Process for producing stabilized polyacrylamide compositions

ABSTRACT

The present application relates to a process for producing a composition comprising at least one acrylamide polymer P and at least one stabilizer St for preventing polymer degradation by molecular oxygen, wherein the acrylamide polymer P is obtained in the form of a polymer gel, and the acrylamide polymer gel having a water content of at least 30% by weight, based on the overall polymer gel, is treated with an aqueous solution SS comprising 0.1% to 50% by weight, based on the overall aqueous solution SS, of the at least one stabilizer St.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to European Application No. 15155996.0,filed Feb. 20, 2015, which is incorporated herein by reference in itsentirety.

The present application relates to a process for producing a compositioncomprising at least one acrylamide polymer P and at least one stabilizerSt for preventing polymer degradation by molecular oxygen, wherein theacrylamide polymer P is obtained in the form of a polymer gel, and theacrylamide polymer gel having a water content of at least 30% by weight,based on the overall polymer gel, is treated with an aqueous solution SScomprising 0.1% to 50% by weight, based on the overall aqueous solutionSS, of the at least one stabilizer St.

High molecular weight homopolyacrylamide and water-solublepolyacrylamide copolymers, for example acrylamide-acrylic acidcopolymers, are known in principle. They are used in many fields ofindustry, for example as thickeners, flocculants, strengtheners forpaper, for oil production or for mining applications.

It is additionally known that thickening water-solublepoly(meth)acrylamide or poly(meth)acrylamide copolymers can be used fortertiary mineral oil production, especially in what is called polymerflooding. For example, it is possible to use copolymers of(meth)acrylamide, acrylic acid and/or sulfo-functional monomers such asATBS (2-acrylamido-2-methylpropane-1-sulfonic acid,H₂C═CH—CO—NH—C(CH₃)₂—CH₂—SO₃H). Additionally known is the use of whatare called hydrophobically associating (meth)acrylamide copolymers inthe mineral oil production sector, especially for tertiary mineral oilproduction (enhanced oil recovery, EOR). These hydrophobicallyassociating copolymers are described, for example, in WO 2010/133527.Details of the use of hydrophobically associating copolymers fortertiary mineral oil production are described, for example, in thereview article by Taylor, K. C. and Nasr-El-Din, H. A. in J. Petr. Sci.Eng. 1998, 19, 265-280.

Polymer flooding involves forcing dilute aqueous polymer solutionsthrough an injection well into a mineral oil-bearing undergroundformation. These polymer solutions flow through fine cavities in theformations in the direction of the production well. As they do so, thepolymer solutions force the mineral oil and possibly the formation waterin the direction of the production well, such that a mixture of mineraloil and water is produced through the production well. The use ofviscous, aqueous polymer solutions rather than water has the advantagethat the polymer solution normally flows through the formation morehomogeneously than water and, as a result, more oil is mobilized thanwhen water is used alone. Methods of polymer flooding are described, forexample, in WO 2012/069478 and WO 2015/024865 A1.

The acrylamide polymers used in polymer flooding typically have a highmolecular weight required to attain the desired thickening action.Typically, the molecular weight (M_(w)) is at least 10⁶ (1 million)g/mol, for example in the range from 1 to 30 million g/mol. Even minorpolymer degradation distinctly reduces the molecular weight in such highmolecular weight polymers.

This generally significantly lowers the viscosity of the polymersolution, which is extremely undesirable for use in tertiary mineral oilproduction (EOR).

The use of acrylamide polymers in polymer flooding places high demandson the stability of the polymers. Polymer flooding typically involvespumping aqueous polymer solutions through the underground rock formationover a period of several months up to several years. The deposittemperature of mineral oil deposits is typically above room temperature,for example 30° C. to 120° C.

One cause of the chemical degradation of polymers may be the presence ofoxygen in the polymer solution. The polymer solutions are typicallyproduced on the oilfield by dissolving solid polymer powders in suitabledissolution facilities, in the course of which attempts are made toexclude oxygen, for example by working under protective gas (such as N₂)and/or using free-radical scavengers (for example sodium bisulfite orhydrazine) and sacrificial reagents. Free-radical scavengers arefrequently used in combination with sacrificial reagents.

In view of the large amounts of polymer solution required in polymerflooding, the production of the polymer solution under protective gas isinconvenient and costly. In order to assure the stability of theacrylamide polymers at elevated temperature and over the long period oftime, it is therefore normally necessary to add various stabilizers tocounteract the harmful influence of light, oxygen and heat. Moreparticularly, oxygen scavengers, free-radical scavengers (for examplethiourea, mercaptobenzothiazole (MBT) or sodium thiocyanate (NaSCN)),sacrificial reagents (e.g. alcohols such as 2-propanol, isopropanol),precipitants and complexing agents are used. The various stabilizerscommonly used in tertiary mineral oil production are described, forexample, in WO 2010/133258.

WO 2015/024865 A1 describes stabilizers for acrylamide polymers,especially sterically hindered piperidine derivatives.

Stabilizers of this kind can be added by the user on dissolution of thesolid polymers. However, many users prefer to use ready-to-usecompositions already comprising the acrylamide polymer and thestabilizer, because this reduces complexity on use. The production ofcompositions from polyacrylamides and polyacrylamide copolymers alreadycomprising one or more stabilizers can be effected in various ways.

JP 74027659 B describes the preparation of polyacrylamides bypolymerization of acrylamide in aqueous solution, wherein a stabilizeris added to the aqueous solution after the polymerization. Subsequently,polymer and stabilizer are precipitated together out of the aqueoussolution by means of suitable precipitants and dried.

U.S. Pat. No. 4,622,356 relates to a process for the free-radicalpolymerization of acrylamide, acrylic acid or2-acrylamide-2-methylpropane sulfonic acid in an aqueous medium, whereina cyclic organic compound having a 1,3-dione moiety is added as astabilizer. The stabilizer can be added to the monomer-mixture directly,or after the polymerization and before drying. Drying of the polymerobtained by polymerization of acrylamide or acrylic acid in aqueoussolution or by emulsion polymerization is carried out in presence of the1, 3-dione compound.

WO 2015/158517 A1 describes a free-radical polymerization process forpreparing acrylamide polymers in the presence of a stabilizer forpreventing polymer degradation by molecular oxygen.

The preparation can be effected by treating acrylamide polymer pelletswith a solution of the stabilizers. This procedure has the drawback thatthe stabilizer has been applied only superficially. In the course oftransport of the polymer pellets, the surface may be abraded. The finesfraction having a high stabilizer content typically collects in thebottom of the transport vessel, while the coarse polymer material aboveis deficient in stabilizer.

It is also possible to dissolve the polymer and the stabilizer in waterand to precipitate a mixture of polymer and stabilizer, but thisinvolves an additional and complex process step.

There are also known techniques in which a stabilizer is added as earlyas in the course of preparation of the polyacrylamides, for example bythe gel polymerization process. U.S. Pat. No. 5,296,577 describes aprocess for preparing polyacrylamides by free-radical polymerization ofacrylamide and optionally further comonomers in an aqueous medium in thepresence of azo initiators and at least 0.1% by weight of the stabilizer2-mercaptobenzthiazole or a salt thereof at a pH of at least 6 within atemperature range from 5 to 100° C. under adiabatic conditions.

DE 30 21 767 A1 describes a process for preparing high molecular weightpolyacrylamides by free-radical polymerization in an aqueous medium, inwhich the polymerization is conducted in the presence of2-mercaptobenzimidazole. The polymerization can be conducted within thetemperature range from 0° C. to 100° C.

It has now been found that, surprisingly, advantageous stabilization ofacrylamide polymer solutions, for example for use in polymer flooding,can be achieved when the polymer gel which is obtained after the gelpolymerization of the (meth)acrylic monomers, preferably without priordrying, is treated with the stabilizer or an aqueous stabilizersolution. In this case, it is advantageously possible to maintain thehigh viscosity of the acrylamide polymer solutions needed for polymerflooding at elevated temperature (about 80° C.) and over a long period(especially over several weeks).

The present invention relates to a process for producing a compositioncomprising at least one water-soluble acrylamide polymer P and at leastone stabilizer St for prevention of polymer degradation by molecularoxygen, comprising the following steps:

-   -   a) providing an aqueous monomer solution MS comprising 20% to        45% by weight, based on the total amount of all the components        of the aqueous monomer solution MS, of at least one        ethylenically unsaturated monomer, at least one monomer being        (meth)acrylamide, at least one initiator I for the free-radical        polymerization, preferably at least one thermal initiator I for        the free-radical polymerization, and at least one solvent So        comprising at least 50% by weight, based on the overall solvent        So, of water;    -   b) polymerizing the aqueous monomer solution MS, preferably        under essentially adiabatic conditions in a gel polymerization,        to obtain the acrylamide polymer P in the form of a polymer gel;    -   c) treating the polymer gel having a water content of at least        30% by weight, preferably of at least 50% by weight, based on        the overall polymer gel, with an aqueous solution SS comprising        0.1% to 50% by weight, based on the overall aqueous solution SS,        of the at least one stabilizer St;    -   d) optionally drying the polymer gel from step c).

By the process of the invention, it is possible to obtain acrylamidepolymers P having improved stability to free-radical degradation(storage stability) compared to the prior art. The acrylamide polymers Pobtained by the process of the invention surprisingly have the followingfurther advantages compared to the prior art:

-   -   better filterability (e.g. Millipore filtration ratio, MPFR) of        the acrylamide polymers P;    -   decrease in insoluble gel fractions in the acrylamide polymers        P;    -   increase in viscosity of the resulting polymer solution of the        acrylamide polymers P.

The process of the invention for producing a composition comprising atleast one acrylamide polymer P and at least one stabilizer St comprisesthe free-radical polymerization of the aqueous monomer solution MS by agel polymerization process. In this process, the monomers are used in acomparatively high concentration in aqueous solution, namely typicallyfrom 20% to 45% by weight. Because of the high concentration, themixture does not remain liquid over the course of polymerization, butbecomes a solid, water-containing polymer gel. The stirring of themixture over the course of the polymerization is of course not possiblebecause of the high viscosity. The polymer gel can be comminuted anddried after the polymerization. In this procedure, added auxiliaries andadditives necessarily remain in the polymer preparation.

A polymer gel in the context of the present invention is understood tomean a composition comprising polymer and at least 30% by weight,preferably at least 50% by weight, preferably in the range from 50% to80% by weight, based on the overall polymer gel, of water, where thepolymer and the water form a homogeneous phase.

The composition produced with the aid of the process of the inventionmay, according to the presence and nature of the optional drying step,comprise 1% to 80% by weight, preferably 5% to 50% by weight, of waterand optionally one of the homogeneously water-miscible solventsdescribed below.

In one embodiment of the invention, the composition produced with theaid of the process of the invention may be a dried polymer composition,for example in the form of powder or pellets, comprising (preferablyconsisting of) the following components:

-   -   70% to 99.8% by weight, preferably 83% to 98.8% by weight, more        preferably 87% to 94.5% by weight, based on the overall        composition, of an acrylamide polymer P described hereinafter;    -   0.1 to 10% by weight, preferably 0.2 to 2% by weight, more        preferably 0.25 to 1% by weight, based on the overall        composition, of at least one stabilizer St described        hereinafter; and    -   0.1% to 20% by weight, preferably 1% to 15% by weight, more        preferably 5% to 12% by weight, based on the overall        composition, of water.

In one embodiment of the invention, the composition produced with theaid of the process of the invention may be a polymer gel or a partlydried polymer gel comprising (preferably consisting of) the followingcomponents:

-   -   20% to 70% by weight, preferably 30% to 50% by weight, more        preferably 30% to 40% by weight, based on the overall        composition, an acrylamide polymer P described hereinafter;    -   0.1 to 10% by weight, preferably 0.2 to 2% by weight, more        preferably 0.25 to 1% by weight, based on the overall        composition, at least one stabilizer St described hereinafter;        and    -   29.9% to 79.9% by weight, preferably 48.8% to 69.8% by weight,        more preferably 55.5% to 69.5% by weight, based on the overall        composition, of water.

The composition may, as well as the stabilizer St, typically compriseone or more further additives, for example selected from initiators,separating agents or further standard additives. Typically, the furtheradditives, if present, are present in an amount of 0.01 to 150 000 ppm.

Acrylamide Polymer P and Monomers in the Monomer Solution MS

An acrylamide polymer in the context of the present invention is apolymer (homopolymer or copolymer) comprising at least one(meth)acrylamide monomer. In the context of the present application, thenotation “(meth)acrylamide” is to encompass acrylamide and/ormethacrylamide. More particularly, “acrylamide polymer” or “acrylamidepolymer P” in the context of the present invention refers to a polymercomprising at least 10% by weight, preferably at least 15% by weight andespecially preferably more than 45% by weight of (meth)acrylamide, basedon the total amount of all the monomers in the acrylamide polymer P. Inthe context of the present invention, a polymer comprising a monomer isunderstood to mean a polymer comprising a monomer unit (in polymerizedform in the polymer chain) based on said monomer. The person skilled inthe art will be aware that this wording in the context of the inventiondoes not describe a proportion of unreacted residual monomer.

In one embodiment of the invention, the acrylamide polymer P preparedmay be a homopolymer consisting essentially of (meth)acrylamide.

In addition, the acrylamide polymer P used may be a copolymer comprising(or consisting of) (meth)acrylamide and at least one further monomer.More particularly, the acrylamide polymer P is a copolymer which, aswell as (meth)acrylamide, comprises an anionic monomer (acidic monomer)as a further monomer, especially selected from acrylic acid,vinylsulfonic acid, acrylamidomethylpropanesulfonic acid and therespective salts. Further monomers used may also be dimethylacrylamideor monomers comprising cationic groups.

In a preferred embodiment, the acrylamide polymer P is a copolymercomprising (meth)acrylamide and at least one anionic, monoethylenicallyunsaturated, hydrophilic monomer (monomer (b)). More particularly, theacrylamide polymer P is a copolymer comprising (meth)acrylamide and atleast one monoethylenically unsaturated, hydrophilic monomer (b).Preferably, the acrylamide copolymer P comprises (meth)acrylamide and atleast one anionic, monoethylenically unsaturated, hydrophilic monomers(b2) comprising at least one acidic group selected from —COOH, —SO₃H and—PO₃H₂ and salts thereof. Especially preferably, the acrylamide polymerP is a copolymer comprising (or consisting essentially of)(meth)acrylamide and acrylic acid, ATBS(2-acrylamido-2-methylpropane-1-sulfonic acid,H₂C═CH—CO—NH—C(CH₃)₂—CH₂—SO₃H) and/or the respective salts.

The term “hydrophilic monomer” in the context of this invention meansthat the corresponding monomers, for example the monomers (b) describedhereinafter, should be soluble in the aqueous solution to be used forpolymerization, i.e. an aqueous solution comprising 20% to 45% by weightof monomers, at the desired use concentration. It is thus not absolutelynecessary for hydrophilic monomers to be used to be miscible with waterwith no gap; instead, it is sufficient when they satisfy the minimumrequirements mentioned. In general, the solubility of the hydrophilicmonomers at room temperature should be at least 50 g/L, preferably atleast 100 g/L and more preferably at least 150 g/L.

In a preferred embodiment, the acrylamide polymer P of the compositionwhich is obtained by the process of the invention has a weight-averagemolecular weight Mw of at least 1*10⁶ g/mol, preferably from 1*10⁶ g/molto 30*10⁶ g/mol, typically about 10-20*10⁶ g/mol.

Preferably, the acrylamide polymer P of the composition which isobtained by the process of the invention has an anionicity in the rangefrom 10% to 60%, preferably from 20% to 40%, more preferably from 20% to35%. Anionicity is understood to mean the molar proportion of themonomers comprising acidic groups based on the total amount ofacrylamide polymer P.

The process of the invention comprises, in step a), the providing of anaqueous monomer solution MS comprising 20% to 45% by weight, based onthe total amount of all the components of the aqueous monomer solutionMS, of at least one ethylenically unsaturated monomer, at least onemonomer being (meth)acrylamide.

Preferably, the monomer solution MS may comprise, as well as(meth)acrylamide, at least one of the following monomers:

-   -   (a) at least one monoethylenically unsaturated, hydrophobically        associating monomer (monomer (a));    -   (b) at least one monoethylenically unsaturated, hydrophilic        monomer (monomer (b)); selected from        -   (b1) uncharged, monoethylenically unsaturated, hydrophilic            monomers (b1), especially selected from the group of            N-methyl(meth)acrylamide, N,N′-dimethyl(meth)acrylamide or            N-methylol(meth)acrylamide;        -   (b2) anionic, monoethylenically unsaturated, hydrophilic            monomers (b2), preferably comprising at least one acidic            group selected from —COOH, —SO₃H and —PO₃H₂ or salts            thereof;        -   (b3) cationic, monoethylenically unsaturated, hydrophilic            monomers (b3), preferably comprising ammonium groups; for            example ammonium derivatives of            N-(ω-aminoalkyl)(meth)acrylamides or ω-aminoalkyl            (meth)acrylates, e.g. 3-trimethylammoniopropylacrylamide            chloride (DIMAPAQUAT), 2-trimethylammonioethyl methacrylate            chloride (MADAME-QUAT) and quaternized dimethylaminoethyl            acrylate (H₂C═CH—CO—O—CH₂CH₂N(CH₃)₃ ⁺Cl), (DMA3Q); and        -   (b4) monoethylenically unsaturated, hydrophilic monomers            (b4) preferably comprising hydroxyl and/or ether groups, for            example hydroxyethyl (meth)acrylate, hydroxypropyl            (meth)acrylate, allyl alcohol, hydroxyvinyl ethyl ether,            hydroxyvinyl propyl ether or hydroxyvinyl butyl ether;    -   (c) at least one monoethylenically unsaturated, hydrophobic        monomer (monomer (c)), especially selected from N-alkyl- and        N,N′-dialkyl(meth)acrylamides, where the number of carbon atoms        in the alkyl radicals together is at least 3, preferably at        least 4, for example N-butyl(meth)acrylamide,        N-cyclohexyl(meth)acrylamide or N-benzyl(meth)acrylamide.

In a preferred embodiment, the proportion of (meth)acrylamide in themonomer solution MS is at least 10% by weight, preferably at least 15%by weight and especially preferably more than 45% by weight, based onthe total amount of all the monomers in the acrylamide polymer P.

In a preferred embodiment, the monomer solution MS comprises thefollowing monomers:

-   -   30% to 100% by weight, preferably 45 to 75% by weight, of        (meth)acrylamide;    -   0% to 70% by weight, preferably 1% to 54% by weight, of at least        one anionic, monoethylenically unsaturated, hydrophilic monomer        (b2);    -   0% to 70% by weight, preferably 1% to 54% by weight, of at least        one cationic, monoethylenically unsaturated, hydrophilic monomer        (b3);    -   0% to 15% by weight of at least one monoethylenically        unsaturated monomer other than (meth)acrylamide and the monomers        (b2) and (b3);    -   where the amounts are each based on the total amounts of all the        monomers in the monomer solution MS. In a preferred embodiment,        the sum total of the abovementioned monomers is 100% by weight.

In a preferred embodiment, the monomer solution MS comprises thefollowing monomers:

-   -   60% to 75% by weight of (meth)acrylamide;    -   25% to 40% by weight of at least one monoethylenically        unsaturated, hydrophilic monomer (b) selected from anionic,        monoethylenically unsaturated, hydrophilic monomers (b2) and        cationic, monoethylenically unsaturated, hydrophilic monomers        (b3),    -   where the amounts are each based on the total amounts of all the        monomers in the monomer solution MS. In a preferred embodiment,        the sum total of the abovementioned monomers is 100% by weight.

In a preferred embodiment, the monomer solution MS comprises thefollowing monomers:

-   -   30% to 100% by weight, preferably 30% to 99.7% by weight, of        (meth)acrylamide;    -   0% to 15% by weight, preferably 0.1% to 15% by weight, of at        least one monoethylenically unsaturated, hydrophobically        associating monomer (a);    -   0% to 70% by weight, preferably 0.1% to 55% by weight,        especially preferably 10% to 50% by weight, of at least one        anionic, monoethylenically unsaturated, hydrophilic monomer        (b2);    -   0% to 70% by weight, preferably 0.1% to 55% by weight,        especially preferably 10% to 50% by weight, of at least one        cationic, monoethylenically unsaturated, hydrophilic monomer        (b3);    -   0% to 15% by weight of at least one monoethylenically        unsaturated monomer other than (meth)acrylamide and the monomers        (a), (b2) and (b3);    -   where the amounts are each based on the total amount of all the        monomers in the copolymer, or in the monomer solution MS, and        with the proviso that the sum total of the monomers mentioned is        100% by weight.

The monomers (a), (b1), (b2), (b3), (b4) and (c) are described in detailhereinafter.

The acrylamide polymer P may especially comprise hydrophobicallyassociating acrylamide copolymers as described in WO 2010/133527 and WO2012/069478. It is additionally also possible to use acrylamidecopolymers comprising cationic groups as described in U.S. Pat. No.7,700,702.

Monomer (a);

The monoethylenically unsaturated, hydrophobically associating monomers(a) (also referred to as amphiphilic monomers (a)) are monoethylenicallyunsaturated monomers having at least one hydrophilic group and at leastone, preferably terminal, hydrophobic group. Monomers of this kind serveto impart hydrophobically associating properties to the acrylamidepolymer P or acrylamide copolymer P.

“Hydrophobically associating copolymers” are understood by those skilledin the art to mean water-soluble copolymers which, as well ashydrophilic units (in a sufficient amount to assure water solubility),have pendant or terminal hydrophobic groups. In aqueous solution, thehydrophobic groups can associate with one another. Because of thisassociative interaction, the viscosity of the aqueous polymer solutionincreases compared to an equivalent polymer merely having no associativegroups.

Suitable monomers (a) especially have the general formulaH₂C═C(R⁵)—R⁶-R⁷ (IIa) where R⁵ is H or methyl, R⁶ is a linkinghydrophilic group and R⁷ is a terminal hydrophobic group. In a furtherembodiment, the monomer (a) may have the general formulaH₂C═C(R⁵)—R⁶-R⁷-R⁸ (IIb) where R⁵, R⁶ and R⁷ are defined as indicated,and R⁸ is a hydrophilic group.

The linking hydrophilic group R⁶ may be a group comprising alkyleneoxide units, for example a group comprising 5 to 50 alkylene oxideunits, joined to the H₂C═C(R⁵)-group in a suitable manner, for exampleby means of a single bond or a suitable linking group, where at least 70mol %, preferably at least 90 mol %, of the alkylene oxide units areethylene oxide units. In addition, it may be a group comprisingquaternary ammonium groups.

In one embodiment of the invention, the hydrophobic R⁷ group comprisesaliphatic and/or aromatic, straight-chain or branched C₈₋₄₀ hydrocarbylradicals R^(7a), preferably C₁₂₋₃₂ hydrocarbyl radicals. In a furtherembodiment, the hydrophobic R⁷ group may be a R^(7b) group comprisingalkylene oxide units having at least 3 carbon atoms, preferably at least4 carbon atoms.

In one embodiment of the invention, the monomers (a) are monomers of thegeneral formulaH₂C═C(R⁵)—O—(—CH₂—CH(R⁸)—O—)_(k)—R^(7a)  (IIc) orH₂C═C(R⁵)—(C═O)—O—(—CH₂—CH(R⁸)—O—)_(k)—R^(7a)  (IId).

In the formulae (IIc) and (IId), R⁵ is defined as indicated above, andthe —O—(—CH₂—CH(R⁸)—O—)_(k)— and —(C═O)—O—(—CH₂—CH(R⁸)—O—)_(k) groupsare specific linking R⁶ groups, i.e. (IIc) is a vinyl ether and (IId) anacrylic ester.

The number of alkylene oxide units k is a number from 10 to 80,preferably 12 to 60, more preferably 15 to 50 and, for example, 20 to40. It will be clear to the person skilled in the art in the field ofthe alkylene oxides that the values mentioned are averages.

The R⁸ radicals are each independently H, methyl or ethyl, preferably Hor methyl, with the proviso that at least 70 mol % of the R⁸ radicalsare H. Preferably at least 80 mol % of the R⁸ radicals are H, morepreferably at least 90 mol %, and they are most preferably exclusivelyH. Said block is thus a polyoxyethylene block which may optionally alsohave certain proportions of propylene oxide and/or butylene oxide units,preferably a pure polyoxyethylene block.

R7a is an aliphatic and/or aromatic, straight-chain or branchedhydrocarbyl radical having 8 to 40 carbon atoms, preferably 12 to 32carbon atoms. In one embodiment, it comprises aliphatic hydrocarbylgroups having 8 to 22, preferably 12 to 18 carbon atoms. Examples ofsuch groups include n-octyl, n-decyl, n-dodecyl, n-tetradecyl,n-hexadecyl or n-octadecyl groups. In a further embodiment, it comprisesaromatic groups, especially substituted phenyl radicals, especiallydistyrylphenyl groups and/or tristyrylphenyl groups.

In a further embodiment of the invention, the monomers (a) are monomersof the general formulaH₂C═C(R⁵)—R⁹—O—(—CH₂—CH(R¹⁰)—O—)_(x)—(—CH₂—CH(R¹¹)—O—)_(y)—(—CH₂—CH₂O—)_(z)—R¹²  (IIe).In the monomers (a) of the formula (IIe), an ethylenic group H₂C═C(R⁵)—is bonded by a divalent linking —R⁹—O— group to a polyoxyalkyleneradical having block structure, where the —(—CH₂—CH(R₁₀)—O—)_(x)—,—(—CH₂—CH(R₁₁)—O—)_(y) and optionally —(—CH₂—CH₂O—)_(z)—R¹² blocks arearranged in the sequence shown in formula (IIe). The transition betweenthe two blocks may be abrupt or else continuous.

In formula (IIe), R⁵ is as already defined, i.e. R⁵ is H or a methylgroup.

R⁹ is a single bond or a divalent linking group selected from the groupconsisting of —(C_(n)H_(2n))— [R^(9a) group], —O—(C_(n′)H_(2n′))—[R^(9b) group] and —C(O)—O—(C_(n″)H_(2n″))— [R^(9c) group]. In each ofsaid formulae, n is a natural number from 1 to 6, n′ and n″ are each anatural number from 2 to 6. In other words, the linking group comprisesstraight-chain or branched aliphatic hydrocarbyl groups having 1 to 6carbon atoms, linked to the ethylenic H₂C═C(R⁵)— group directly, via anether group —O— or via an ester group —C(O)—O—. Preferably, the—(C_(n)H_(2n))—, —(C_(n′)H_(2n′))— and —(C_(n″)H_(2n″))-groups arelinear aliphatic hydrocarbyl groups.

Preferably, the R^(9a) group is a group selected from —CH₂—, —CH₂—CH₂—and —CH₂—CH₂—CH₂—, more preferably a methylene group —CH₂—.

Preferably, the R^(9b) group is a group selected from —O—CH₂—CH₂—,—O—CH₂—CH₂—CH₂— and —O—CH₂—CH₂—CH₂—CH₂—, more preferably—O—CH₂—CH₂—CH₂—CH₂—.

Preferably, the R^(9c) group is a group selected from —C(O)—O—CH₂—CH₂—,—C(O)O—CH(CH₃)—CH₂—, —C(O)O—CH₂—CH(CH₃)—, —C(O)O—CH₂—CH₂—CH₂—CH₂— and—C(O)O—CH₂—CH₂—CH₂—CH₂—CH₂—CH₂—, more preferably —C(O)—O—CH₂—CH₂— and—C(O)O—CH₂—CH₂—CH₂—CH₂— and most preferably —C(O)—O—CH₂—CH₂—.

More preferably, the R⁹ group is an R^(9b) group, most preferably—O—CH₂—CH₂—CH₂—CH₂—.

In the —(—CH₂—CH(R¹⁰)—O—)_(x) block, the R¹⁰ radicals are eachindependently H, methyl or ethyl, preferably H or methyl, with theproviso that at least 70 mol % of the R¹⁰ radicals are H. Preferably, atleast 80 mol % of the R¹⁰ radicals are H, more preferably at least 90mol %, and they are most preferably exclusively H. Said block is thus apolyoxyethylene block which may optionally also have certain proportionsof propylene oxide and/or butylene oxide units, preferably a purepolyoxyethylene block.

The number of alkylene oxide units x is a number from 10 to 50,preferably 12 to 40, more preferably 15 to 35, even more preferably 20to 30 and, for example, about 22 to 25. It will be clear to the personskilled in the art in the field of the polyalkylene oxides that thenumbers mentioned are averages of distributions.

In the second block —(—CH₂—CH(R¹¹)—O—)_(y)—, the R¹¹ radicals are eachindependently hydrocarbyl radicals of at least 2 carbon atoms, forexample 2 to 10 carbon atoms, preferably 2 or 3 carbon atoms. This maybe an aliphatic and/or aromatic, linear or branched hydrocarbyl radical.Preference is given to aliphatic radicals.

Examples of suitable R¹¹ radicals include ethyl, n-propyl, n-butyl,n-pentyl, n-hexyl, n-heptyl, n-octyl, n-nonyl or n-decyl, and alsophenyl. Examples of preferred radicals include ethyl, n-propyl, n-butyl,n-pentyl and particular preference is given to ethyl and/or n-propylradicals. The —(—CH₂—CH(R¹¹)—O—)_(y)— block is thus a block consistingof alkylene oxide units having at least 4 carbon atoms.

The number of alkylene oxide units y is a number from 5 to 30,preferably 8 to 25.

In formula (IIe), z is a number from 0 to 5, for example 1 to 4, i.e.the terminal block of ethylene oxide units is thus merely optionallypresent. In a preferred embodiment of the invention, a mixture of atleast two monomers (a) of the formula (IIe) may be used, in which casethe R⁵, R⁹, R¹⁰, R¹¹, R¹² radicals and the indices x and y are the samein each case; only in one of the monomers is z=0 while z>0 in the other,preferably 1 to 4.

The R¹² radical is H or a preferably aliphatic hydrocarbyl radicalhaving 1 to 30 carbon atoms, preferably 1 to 10 and more preferably 1 to5 carbon atoms. Preferably, R¹² is H, methyl or ethyl, more preferably Hor methyl and most preferably H.

The hydrophobically associating monomers (a) of the formulae (IIc),(IId) and (IIe), acrylamide copolymers comprising these monomers and thepreparation thereof are known in principle to those skilled in the art,for example from WO 2010/133527 and WO 2012/069478.

In a further embodiment, the associative monomer (a) is a cationicmonomer of the general formula H₂C═C(R⁵)—C(═O)O—R¹³—N⁺(R¹⁴)(R¹⁵)(R¹⁶) X⁻(IIf) or H₂C═C(R⁵)—C(═O)N(R¹⁷)—R¹³—N⁺(R¹⁴)(R¹⁵)(R¹⁶) X⁻ (IIg).

In the formulae (IIf) and (IIg), R⁵ is as defined above.

R¹³ is an alkylene radical, especially a 1,ω-alkylene radical having 1to 8 carbon atoms, preferably 2 to 4 carbon atoms and especially 2 or 3carbon atoms. Examples include —CH₂—, —CH₂CH₂—, —CH₂CH₂CH₂— and—CH₂CH₂CH₂CH₂—. Particular preference is given to —CH₂CH₂— and—CH₂CH₂CH₂—.

R¹³, R¹⁴ and R¹⁵ are each independently H or an alkyl group having 1 to4 carbon atoms, preferably H or methyl. R¹³ is preferably H and R¹⁴ andR¹⁵ are preferably each methyl. X⁻ is a negatively charged counterion,especially a halide ion selected from F⁻, Cl⁻, Br⁻ or I⁻, preferably Cl⁻and/or Br⁻.

R¹⁶ is an aliphatic and/or aromatic, linear or branched hydrocarbylgroup having 8 to 30 carbon atoms, preferably 12 to 18 carbon atoms. R¹⁶may especially comprise aliphatic hydrocarbyl radicals having 8 to 18,preferably 12 to 18, carbon atoms. Examples of such groups includen-octyl, n-decyl, n-dodecyl, n-tetradecyl, n-hexadecyl or n-octadecylgroups, preferably n-dodecyl, n-tetradecyl, n-hexadecyl or n-octadecylgroups.

Preference is given to a monomer of the general formula (IIg). Examplesof such monomers compriseN-(meth)acrylamidopropyl-N,N-dimethyl-N-dodecylammonium chloride,N-(meth)acrylamidopropyl-N,N-dimethyl-N-tetradecylammonium chloride,N-(meth)acrylamidopropyl-N,N-dimethyl-N-hexadecylammonium chloride orN-(meth)acrylamidopropyl-N,N-dimethyl-N-octadecylammonium chloride orthe corresponding bromides. Monomers of this kind and acrylamidecopolymers having such monomers are known and are described, forexample, in U.S. Pat. No. 7,700,702 B2.

Further preferably, the acrylamide polymer P may be a copolymer asdescribed in WO 2012/069478. Preferably, the monomer solution MS,comprises, as monomers:

-   -   (a) 0.1% to 15% by weight of at least one monoethylenically        unsaturated, hydrophobically associating monomer (a), and    -   (b) 85% to 99.9% by weight of at least two different        monoethylenically unsaturated, hydrophilic monomers (b), where        the monomers (b) are at least        -   (b1) at least one uncharged, monoethylenically unsaturated,            hydrophilic monomer (b1) selected from the group of            (meth)acrylamide, N-methyl(meth)acrylamide,            N,N′-dimethyl(meth)acrylamide and            N-methylol(meth)acrylamide, with the proviso that at least            10% by weight, preferably at least 15% by weight and            especially preferably more than 45% by weight, based on the            total amount of all the monomers in the acrylamide polymer            P, of (meth)acrylamide is present;        -   (b2) at least one anionic, monoethylenically unsaturated,            hydrophilic monomer (b2) which trades at least one acidic            group selected from the group of —COOH, —SO₃H and —PO₃H₂ or            salts thereof,            where the figures stated, unless stated otherwise, are each            based on the total amount of all the monomers in the            copolymer, or in the monomer solution MS.            Monomers (b):

The acrylamide copolymer or the monomer solution MS may preferablycomprise at least one monoethylenically unsaturated, hydrophilic monomer(b), with the proviso that at least 10% by weight, preferably at least15% by weight and especially preferably more than 45% by weight of(meth)acrylamide, based on the total amount of all the monomers in theacrylamide polymer P or in the monomer solution MS, is present.

Preferably, the hydrophilic monomers (b) have functional groups selectedfrom the group consisting of carbonyl groups >C═O, ether groups —O—,especially polyethylene oxide groups —(CH₂—CH₂—O—)_(n)— where n ispreferably a number from 1 to 200, hydroxyl groups —OH, primary,secondary or tertiary amino groups, ammonium groups, amide groups—C(O)—NH—, carboxamide groups —C(O)—NH₂ or acidic groups such ascarboxyl groups —COOH, sulfo groups —SO₃H, phosphonic acid groups —PO₃H₂or phosphoric acid groups —OP(OH)₃. Examples of preferred functionalgroups comprise hydroxyl groups —OH, carboxyl groups —COOH, sulfo groups—SO₃H, carboxamide groups —C(O)—NH₂, amide groups —C(O)—NH— andpolyethylene oxide groups —(CH₂—CH₂—O—)_(n)—H where n is preferably anumber from 1 to 200.

The functional groups may be attached directly to the ethylenic group,or else are bonded via one or more linking hydrocarbyl groups to theethylenic group.

More preferably, the monoethylenically unsaturated hydrophilic monomers(b) used are miscible with water in any ratio. However, it is sufficientfor execution of the invention that the monomers (b) are soluble in themonomer solution MS used for polymerization at the desire useconcentration. In general, the solubility of the monomers (b) in waterat room temperature should be at least 50 g/l, preferably at least 100g/l and more preferably at least 150 g/l.

The amount of all the hydrophilic monomers (b) in the acrylamide polymerP or in the monomer solution MS is typically 85% to 99.9% by weight,based on the total amount of all the monomers in the acrylamide polymerP, preferably 90% to 99.8% by weight, with the proviso that at least 10%by weight, preferably at least 15% by weight and especially preferablymore than 45% by weight of (meth)acrylamide, based on the total amountof all the monomers in the acrylamide polymer P, is present.

The amount of the uncharged, hydrophilic monomers (b1) here is generally10 to 95% by weight, preferably 30 to 95% by weight, preferably 30 to85% by weight and more preferably 30 to 70% by weight, based on thetotal amount of all the monomers used, with the proviso that at least10% by weight, preferably at least 15% by weight and especiallypreferably more than 45% by weight of (meth)acrylamide, based on thetotal amount of all the monomers in the acrylamide polymer P, ispresent.

If the acrylamide copolymer P comprises only uncharged monomers (b1) andanionic monomers (b2), it has been found to be useful to use theuncharged monomers (b1) including (meth)acrylamide in an amount of 30 to95% by weight and the anionic monomers (b2) in an amount of 4.9 to 69.9%by weight, the amount being based in each case on the total amount ofall the monomers used. In this embodiment, the monomers (b1) arepreferably used in an amount of 30 to 80% by weight and the anionicmonomers (b2) in an amount of 19.9 to 69.9% by weight, and the monomers(b1) are more preferably used in an amount of 40 to 70% by weight andthe anionic monomers (b2) in an amount of 29.9 to 59.9% by weight.

If the copolymer comprises uncharged monomers (b1), anionic monomers(b2) and cationic monomers (b3), it has been found to be useful to usethe uncharged monomers (b1) including (meth)acrylamide in an amount of30 to 95% by weight and the anionic (b2) and cationic monomers (b3)together in an amount of 4.9 to 69.9% by weight, with the proviso thatthe molar ratio (b2)/(b3) is 0.7 to 1.3. Preferably, the molar ratio(b2)/(b3) is 0.8 to 1.2 and, for example, 0.9 to 1.1. This measure makesit possible to obtain copolymers which are particularly insensitive tosalt burden. In this embodiment, the monomers (b1) are preferably usedin an amount of 30 to 80% by weight and the anionic and cationicmonomers (b2)+(b3) together in an amount of 19.9 to 69.9% by weight, andthe monomers (b1) are more preferably used in an amount of 40 to 70% byweight and the anionic and cationic monomers (b2)+(b3) together in anamount of 29.9 to 59.9% by weight, and the molar ratio already mentionedshould be complied with in each case.

Monomers (b1):

The monomer solution MS may typically comprise, as well as(meth)acrylamide, at least one other uncharged, monoethylenicallyunsaturated, hydrophilic monomer (b1) selected from the group ofN-methyl(meth)acrylamide, N,N′-dimethyl(meth)acrylamide orN-methylol(meth)-acrylamide, with the proviso that at least 10% byweight, preferably at least 15% by weight and especially preferably morethan 45% by weight of (meth)acrylamide, based on the total amount of allthe monomers in the acrylamide polymer P, is present.

It is additionally possible to use, as monomer (b1), exclusively(meth)acrylamide, especially acrylamide.

Monomers (b2):

In a preferred embodiment, the monomer solution MS comprises, as well as(meth)acrylamide, additionally at least one hydrophilic,monoethylenically unsaturated anionic monomer (b2) comprising at leastone acidic group selected from the group of —COOH, —SO₃H and —PO₃H₂ orsalts thereof. Preference is given to monomers comprising —COOH groupsand/or —SO₃H groups, particular preference to monomers comprising —SO₃Hgroups. It will be appreciated that the salts of the acidic monomers mayalso be involved. Suitable counterions comprise especially alkali metalions such as Li⁺, Na⁺ or K⁺, and also ammonium ions such as NH₄ ⁺ orammonium ions having organic radicals.

Examples of monomers comprising COOH groups include acrylic acid,methacrylic acid, crotonic acid, itaconic acid, maleic acid or fumaricacid. Preference is given to acrylic acid and/or salts thereof,especially sodium acrylate.

Examples of monomers (b2) comprising sulfo groups include vinylsulfonicacid, allylsulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid,2-methacrylamido-2-methylpropanesulfonic acid,2-acrylamidobutanesulfonic acid, 3-acrylamido-3-methyl-butanesulfonicacid or 2-acrylamido-2,4,4-trimethylpentanesulfonic acid. Preference isgiven to vinylsulfonic acid, allylsulfonic acid or2-acrylamido-2-methylpropanesulfonic acid and particular preference to2-acrylamido-2-methylpropanesulfonic acid (ATBS) or salts thereof.

Examples of monomers (b2) comprising phosphonic acid groups includevinylphosphonic acid, allylphosphonic acid,N-(meth)acrylamidoalkylphosphonic acids or(meth)acryloyloxyalkylphosphonic acids, preferably vinylphosphonic acid.

Preferably, monomer (b2) may be selected from the group consisting ofacrylic acid, methacrylic acid, crotonic acid, itaconic acid, maleicacid, fumaric acid, vinylsulfonic acid, allylsulfonic acid,2-acrylamido-2-methylpropanesulfonic acid (ATBS),2-methacrylamido-2-methylpropanesulfonic acid,2-acrylamidobutanesulfonic acid, 3-acrylamido-3-methylbutanesulfonicacid, 2-acrylamido-2,4,4-trimethylpentanesulfonic acid, vinylphosphonicacid, allylphosphonic acid, N-(meth)acrylamidoalkylphosphonic acids and(meth)acryloyloxyalkylphosphonic acids, more preferably from acrylicacid and/or ATBS or salts thereof.

Further preferably, the monomer solution MS comprises, as monomers,(meth)acrylamide and at least two further monomers (b2) comprisingdifferent acidic groups. More particularly, the monomers (b2) comprisingacidic groups are a monomer comprising the —SO₃H group (e.g.2-acrylamido-2-methylpropanesulfonic acid (ATBS)) and a monomercomprising the —COOH group (e.g. acrylic acid).

Especially preferably, the monomer solution MS comprises at least onemonomer selected from the group consisting of (meth)acrylamide,2-acrylamido-2-methylpropanesulfonic acid (ATBS), acrylic acid and therespective salts thereof, with the proviso that at least 10% by weight,preferably at least 15% by weight and especially preferably more than45% by weight of (meth)acrylamide, based on the total amount of all themonomers in the acrylamide polymer P, is present. Especially preferably,the monomer solution MS comprises (meth)acrylamide,2-acrylamido-2-methylpropanesulfonic acid (ATBS), acrylic acid and/orthe respective salts thereof.

For the sake of completeness, it should be mentioned that the monomers(b1) can under some circumstances be hydrolyzed at least partly to(meth)acrylic acid in the course of preparation and use. The acrylamidecopolymers prepared in accordance with the invention may accordinglycomprise (meth)acrylic acid units even if no (meth)acrylic acid units atall have been used for the synthesis. The tendency of the monomers (b1)to be hydrolyzed increases with increasing content of sulfo groups.Accordingly, the presence of sulfo groups in the acrylamide copolymerused is advisable.

Monomers (b3):

The monomer solution MS may optionally comprise, as well as(meth)acrylamide, at least one monoethylenically unsaturated, cationicmonomer (b3) having ammonium groups.

Suitable cationic monomers (b3) comprise especially monomers havingammonium groups, especially ammonium derivatives ofN-(ω-aminoalkyl)(meth)acrylamides or ω-aminoalkyl (meth)acrylates.

More particularly, monomers (b3) having ammonium groups may be compoundsof the general formulae H₂C═C(R^(8P))—CO—NR^(9P)—R^(10P)—N(R^(11P))₃ ⁺M⁻ (Va) and/or H₂C═C(R^(8P))—COO—R^(10P)—N(R^(11P))₃ ⁺ X⁻ (Vb). In theseformulae, R^(8P) is H or methyl, R^(9P) is H or a C₁- to C₄-alkyl group,preferably H or methyl and R^(10P) is a preferably linear C₁- toC₄-alkylene group, for example a 1,2-ethylene group —CH₂—CH₂— or a1,3-propylene group —CH₂—CH₂—CH₂—.

The R^(11P) radicals are each independently C₁- to C₄-alkyl radicals,preferably methyl or a group of the general formula —R^(12P)—SO₃H whereR^(12P) is a preferably linear C₁- to C₄-alkylene group or a phenylgroup, with the proviso that generally not more than one of the R^(11P)substituents is a substituent having sulfo groups. More preferably, thethree R^(11P) substituents are methyl groups, meaning that the monomerhas an —N(CH₃)₃ ⁺ group. M⁻ in the above formula is a monovalent anion,for example Cl⁻. It will be appreciated that M⁻ may also be acorresponding fraction of a polyvalent anion, although this is notpreferred. Examples of preferred monomers (b3) of the general formula(Va) or (Vb) comprise salts of 3-trimethylammoniopropyl(meth)acrylamidesor 2-trimethylammonioethyl (meth)acrylates, for example thecorresponding chlorides such as 3-trimethylammoniopropylacrylamidechloride (DIMAPAQUAT) and 2-trimethylammonioethyl methacrylate chloride(MADAME-QUAT).

In a preferred embodiment, the monomer solution MS comprises at leastone (meth)acrylamide and at least one cationically modifiedpolyacrylamide, especially DMA3Q, quaternized dimethylaminoethylacrylate, (H₂C═CH—CO—O—CH₂CH₂N(CH₃)₃ ⁺ Cl), generally —N(CH₃)₂—R(R=long-chain alkyl).

Monomers (b4)

The monomer solution MS may additionally comprise furthermonoethylenically unsaturated, hydrophilic monomers (b4) other than thehydrophilic monomers (b1), (b2) and (b3). Examples of such monomersinclude monomers comprising hydroxyl and/or ether groups, for examplehydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, allylalcohol, hydroxyvinyl ethyl ether, hydroxyvinyl propyl ether,hydroxyvinyl butyl ether or compounds of the formulaH₂C═C(R^(1P))—COO—(—CH₂—CH(R^(13P))—O—)_(b)—R^(14P) (VIa) orH₂C═C(R^(1P))—O—(—CH₂—CH(R^(13P))—O—)_(b)—R^(14P) (VIb) where R^(1P) isH or a methyl group and b is a number from 2 to 200, preferably 2 to100. The R^(13P) radicals are each independently H, methyl or ethyl,preferably H or methyl, with the proviso that at least 50 mol % of theR^(13P) radicals are H. Preferably at least 75 mol % of the R^(13P)radicals are H, more preferably at least 90 mol %, and they are mostpreferably exclusively H.

The R^(14P) radical is H, methyl or ethyl, preferably H or methyl.Further examples of monomers (b4) include N-vinyl derivatives, forexample N-vinylformamide, N-vinylacetamide, N-vinyl-pyrrolidone orN-vinylcaprolactam, and also vinyl esters, for example vinyl formate orvinyl acetate. N-Vinyl derivatives can be hydrolyzed afterpolymerization to vinylamine units, and vinyl esters to vinyl alcoholunits.

Monomers (c)

As well as the above-described monomers, the monomer solution MS maycomprise further monoethylenically unsaturated monomers (c). It will beappreciated that it is also possible for mixtures of a plurality ofdifferent monomers (c) to be present.

Such monomers can be used for fine control of the properties of theacrylamide polymer P. If they are present at all, the amount of suchoptional monomers (c) may be up to 14.9% by weight, preferably up to9.9% by weight, more preferably up to 4.9% by weight, based in each caseon the total amount of all the monomers. Most preferably, no monomers(c) are present.

The monomers (c) may, for example, be monoethylenically unsaturatedmonomers which have a more hydrophobic character than the hydrophilicmonomers (b) and which are accordingly only slightly water-soluble. Ingeneral, the solubility of the monomers (c) in water at room temperatureis less than 50 g/l, especially less than 30 g/l. Examples of suchmonomers include N-alkyl- and N,N′-dialkyl(meth)acrylamides, where thenumber of carbon atoms in the alkyl radicals together is at least 3,preferably at least 4. Examples of such monomers includeN-butyl(meth)acrylamide, N-cyclohexyl(meth)acrylamide orN-benzyl(meth)acrylamide.

Step a)

The process of the invention comprises, in step a, the providing of amonomer solution MS comprising (meth)acrylamide and optionally furthermonomers (a), (b) and/or (c) described below, at least one initiator I,preferably a thermal initiator, for free-radical polymerization and atleast one solvent So.

The monomer solution MS has a concentration of monomers in the rangefrom 20% to 45% by weight, preferably 25% to 40% by weight, morepreferably 30% to 40% by weight, based on the overall monomer solutionMS. According to the invention, the monomer solution MS comprises, asmonomer, (meth)acrylamide and optionally one or more of the monomers(a), (b) and/or (c) described, preferably one or more of the monomers(a) and (b), especially preferably one or more of the monomers (b1),(b2) and (b3) described.

Preferably, the monomer solution MS comprises 2% to 39.5% by weight,based on the overall monomer solution MS, of (meth)acrylamide and 0.5%to 23% by weight, based on the overall monomer solution MS, of one ormore of the monomers (a) and (b) described.

Suitable compositions and quantitative ratios in the monomer solutionsMS have already been described in detail above, and explicit referenceis made thereto at this point.

Acidic or basic monomers may be fully or partly neutralized prior to thepolymerization. Preferably, the pH of the monomer solution MS is in therange from 4 to 9, preferably in the range from 5 to 8.

Preferably, the above-described monomer solution MS comprises at leastone standard initiator I for free-radical polymerization, especiallyselected from peroxide initiators, azo initiators and redox initiators.Particular preference is given to using an azo initiator, especially atleast one azo initiator selected from 4,4′-azobis(4-cyanovaleric acid)(ACVA), azobis(isobutyronitrile) (AIBN), dibenzoyl peroxide (DBPO) and2,2′-azobis(2-methylpropionamidine) dihydrochloride.

Further preferably, the initiator I used is a combination of at leastone azo initiator and at least one redox initiator.

Typical peroxide initiators are, for example, dibenzoyl peroxide (DBPO),cyclohexylsulfonylacetyl peroxide (SPO), diisopropyl peroxydicarbonate(DIPP), butyl peroxypivalate, dilauryl peroxide (DLPO), tert-butylhydroperoxide (t-BHP) and cumene hydroperoxide. Typical azo initiatorsare, for example, 4,4′-azobis-4-cyanovaleric acid (ACVA),2,2′-azobis(2-methylpropionamidine) dihydrochloride,2,2′-azobis(2-methylpropionitrile), 2,2′-azobis(2-methylbutanenitrile),2,2′-azobis(2,4-dimethylvaleronitrile), 1,1′-azobis(cyanocyclo-hexane),1,1′-azobis(N,N-dimethylformamide), 2,2′-azobis(2-methylbutyronitrile),2,2′-azobis(4-methoxy-2,4-dimethylvaleronitrile),2,2′-azobis(2,4,4-trimethylpentane). Typical redox initiators are, forexample, mixtures of an oxidizing agent, such as hydroperoxide,peroxodisulfates or the abovementioned peroxide compounds, and areducing agent, such as iron(II) salts, silver(I) salts, cobalt(II)salts, sulfites, hydrogensulfites or thiosulfates.

Preferably, the monomer solution MS comprises 300 to 1000 ppm,preferably 600 to 800 ppm, based on the overall monomer solution MS, ofat least one initiator, especially selected from4,4′-azobis(4-cyanovaleric acid) (ACVA), azobis(isobutyronitrile)(AIBN), dibenzoyl peroxide (DBPO), 2,2′-azobis(2-methylpropionamidine)dihydrochloride and tert-butyl hydroperoxide (t-BHP), more preferably4,4′-azobis(4-cyanovaleric acid) (ACVA), azobis(isobutyronitrile) (AIBN)and 2,2′-azobis(2-methylpropionamidine) dihydrochloride.

Preferably, the monomer solution MS comprises, as redox initiator, 1 to50 ppm, based on the overall monomer solution MS, of at least oneoxidizing agent, preferably an abovementioned peroxide compound, forexample tert-butyl hydroperoxide (t-BHP), and 1 to 50 ppm, based on theoverall monomer solution MS, of at least one reducing agent, preferablyan abovementioned sulfite.

Preferably, the monomer solution MS comprises, as initiator I, acombination of an azo initiator and a redox initiator in theabove-described amount ranges.

In the context of the present invention, ppm means mg/kg.

As solvent So, the monomer solution MS preferably comprises water, or amixture of water and one or more water-miscible organic solvents, wherethe proportion of water is generally at least 85% by weight, preferablyat least 95% by weight, more preferably at least 98% by weight, based ineach case on the sum total of all the solvents So. Organic solvents usedmay be known polar water-miscible solvents, such as alcohols or dimethylsulfoxide (DMSO). Organic solvents used may especially be water-misciblealcohols such as methanol, ethanol or propanol. In a preferredembodiment, the solvent So used is exclusively water.

Preference is given to using a monomer solution MS comprising 20% to 45%by weight, preferably 25% to 40% by weight, more preferably 30% to 40%by weight, based on the overall monomer solution MS, of monomers,especially selected from (meth)acrylamide and the optional monomers (a)to (c) described, preferably (a) and (b), especially preferably (b1),(b2) and/or (b3), with the proviso that at least 10% by weight,preferably at least 15% by weight and especially preferably more than45% by weight, based on the total amount of all the monomers, is(meth)acrylamide, 1 to 1000 ppm of an abovementioned free-radicalinitiator I and at least one solvent So, preferably water, where all thefigures are based on the overall monomer solution MS. In a preferredembodiment, the amounts of (meth)acrylamide monomer, optional furthermonomers (a), (b) and/or (c), initiator I and solvent So add up to 100%by weight.

Step b)

The process of the invention comprises, in step b), the polymerizing ofthe monomer solution MS to give the acrylamide polymer P in the form ofa polymer gel.

The polymerizing of the monomer solution MS can be initiated, forexample, directly by adding the at least one initiator I for thefree-radical polymerization (part of step a)) or by increasing thetemperature of the monomer solution MS already comprising the initiatorI. The polymerizing of the monomer solution MS can additionally beinitiated by irradiation with UV light.

The polymerization of (meth)acrylamide and optionally of the furthermonomers (a), (b) and/or (c) described below by means of free-radicalpolymerization in what is called a gel polymerization is described inprinciple in the prior art. The polymerization in step b) can beeffected, for example, as described in WO 2012/069478 and WO2010/133527.

Preferably, the polymerization in step b) is conducted under adiabaticconditions or at least essentially adiabatic conditions, in which casethe monomer solution is heated under the influence of the heat ofpolymerization formed and a polymer gel is obtained. Preferably, step b)is an adiabatic gel polymerization.

Adiabatic conditions or at least essentially adiabatic conditions areunderstood by the person skilled in the art to mean that no heat issupplied to the reactor from outside during the polymerization and thereactor is not cooled during the reaction. It will be clear to theperson skilled in the art—according to the internal temperature of thereactor and the ambient temperature—that certain amounts of heat can bereleased and absorbed via the reactor wall because of temperaturegradients. This effect normally plays an ever smaller role withincreasing reactor size.

Typically, the monomer solution MS is cooled to −5° C. to 5° C.,preferably to about 0° C., and then polymerized photochemically and/orthermally. Preferably, the polymerization is effected by adding suitableinitiators I for the free-radical polymerization, e.g. peroxides (suchas tert-butyl hydroperoxide), azo compounds (such asazobis(isobutyronitrile)) or redox initiators. Preference is given tousing a combination of one or more azo compounds and one or more redoxinitiators. Suitable initiators I have been described above.Photochemical polymerization is typically initiated at temperatures of−5 to 10° C.; thermal polymerization is typically initiated attemperatures of −5 to 50° C. It is also possible to combinephotochemical and thermal polymerization with one another. During thepolymerization, the temperature generally rises because of the heat ofreaction to 60 to 100° C., preferably 80 to 95° C.

Typically, the monomer solution MS or the reaction mixture is notstirred during the polymerization. The gel polymerization can beundertaken, for example, in a tubular reactor as described by GB1,054,028. Particularly advantageously, the polymerization can beconducted using conical reactors as described, for example, by U.S. Pat.No. 5,633,329 or 7,619,046.

Further details regarding performance of a gel polymerization aredescribed, for example, in WO 2010/133527 (pages 18 and 19) and DE 102004 032 304 A1 (paragraphs [0037] to [0041]).

The polymerization in step b), especially the adiabatic gelpolymerization, can typically be effected in a continuous or batchwiseprocess.

In general, the polymer gel obtained in step b) is solid and does notflow out of the polymerization reactor without additional measures. Ifthe polymerization reactor used has mechanical aids, for example amovable ram disposed in the reactor (for example as described in GB1,054,028), the polymer gel can be expressed using such aids.

The expression of the polymer gel from the polymerization reactor canalso be undertaken, for example, using gases. For this purpose, a gas istypically injected at the top of the polymerization reactor. For thispurpose, it is possible to use any gases which cannot react with thepolymer gel. Advantageously, it is possible for this purpose to indicateinert gases, such as nitrogen, carbon dioxide or argon, at the top ofthe reactor. But it is also possible to use other gases, for examplecompressed air. Alternatively, an inert liquid, especially a precipitantfor the acrylamide polymer P, can be injected at the top of the reactor.The pressure of the gas or liquid is chosen suitably by the personskilled in the art and may, for example, be 2*10⁵ to 65*10⁵ Pa,especially 4*10⁵ to 25*10⁵ Pa. The pressure is especially chosen suchthat the polymer gel is discharged homogeneously from the reactor. Theexpression the polymer gel from the polymerization reactor is especiallyconducted in the case of a batchwise polymerization in step b). It ispossible here that a first coarse comminution of the polymer gel(optional step e)) is effected at this early stage.

In the case of a continuous polymerization in step b), the resultantpolymer gel is typically discharged from the polymerization reactor withthe aid of a screw (conveying screw). In this case, a first coarsecomminution of the polymer gel is typically effected (optional step e).

Step c)

The process of the invention comprises, in step c), the treating of thepolymer gel having a water content of at least 30% by weight, preferablyof at least 50% by weight, based on the overall polymer gel, with anaqueous solution SS comprising 0.1% to 50% by weight, based on theoverall aqueous solution SS, of the at least one stabilizer St.

Stabilizer St

According to the invention, the aqueous solution SS comprises at leastone stabilizer St for prevention of polymer degradation by molecularoxygen. More particularly, the stabilizer St is what is called afree-radical scavenger, i.e. compounds which can react with freeradicals, such that these reactive oxygen species can no longer attackand hence degrade the polymer. Free radicals may, for example, bereactive oxygen species which are formed by UV light or redox processes.Typically, as described above, in the course of polymer flooding, thereis degradation of the polyacrylamide and hence an unwanted drop in theviscosity of the polymer solution in the course of flooding.

Stabilizers of this kind are known in principle to those skilled in theart. For example, they may be sulfur compounds, sterically hinderedamines, N-oxides, nitroso compounds, aromatic hydroxyl compounds orketones. Suitable stabilizers St are described, for example, in WO2010/133258.

Examples of sulfur compounds comprise thiourea; substituted thioureassuch as N,N′-dimethylthiourea, N,N′-diethylthiourea,N,N′-diphenylthiourea; thiocyanates, for example ammonium thiocyanate orpotassium thiocyanate; tetramethylthiuram disulfide; mercaptans such as2-mercaptobenzothiazol or 2-mercaptobenzimidazole or the alkali metalsalts thereof (for example the sodium salts); sodiumdimethyldithiocarbamate; 2,2′-dithiobis(benzothiazole) and4,4′-thiobis(6-t-butyl-m-cresol).

Preferably, the at least one stabilizer St is an organic sulfurcompound. An organic sulfur compound in the context of the presentinvention is an organic compound having at least one sulfur-containingfunctional group, especially a group selected from —SCN (thiocyanategroup), —NCS (isothiocyanate group), —NR′—C(═S)—NR′— (thiourea group);—NR′—C(═S)—NR′₂—S—H (thiol group), —S-M (thiolate group) where M is ametal ion, especially an alkali metal ion, —S—S—R′ (disulfide groups),—NR′—C(═O)—S—R′ (thiolourethane group), —NR′—C(═S)—O—R′ (thionourethanegroup), —NR′—C(═S)—S—R′ (dithiourethane group), where R′ is H or anorganic hydrocarbyl radical. More particularly, the stabilizer St is anorganic sulfur compound selected from thiols, thiophenols, sulfides,disulfides, sulfoxides, thioureas and thiourethanes (thiocarbamates),e.g. thiolourethanes, thionourethane, dithiourethanes.

Further examples of the stabilizer St include dicyandiamide, guanidine,cyanamide, paramethoxyphenol, 2,6-di-t-butyl-4-methylphenol,butylhydroxyanisole, 8-hydroxyquinoline, 2,5-di(t-amyl)hydroquinone,5-hydroxy-1,4-naphthoquinone, 2,5-di(t-amyl)hydroquinone, dimedone,propyl 3,4,5-trihydroxybenzoate, ammonium N-nitrosophenylhydroxylamine,4-hydroxy-2,2,6,6-tetramethyoxylpiperidine,(N-(1,3-dimethylbutyl)N′-phenyl-p-phenylenediamine or1,2,2,6,6-pentamethyl-4-piperidinol (PMP).

Preferably, the stabilizer St comprises sterically hindered amines, forexample 1,2,2,6,6-pentamethyl-4-piperidinol, and/or sulfur compounds,preferably mercapto compounds, especially 2-mercaptobenzothiazole or2-mercaptobenzimidazole or the respective salts thereof, for examplesodium 2-mercaptobenzothiazole.

In the process of the invention, preference is given to using stericallyhindered amines (HALS stabilizers) as stabilizer St, especiallypreferably sterically hindered piperidine derivatives, for example1,2,2,6,6-pentamethyl-4-piperidinol (PMP).

In one embodiment, the stabilizer St is at least one compound selectedfrom the group consisting of thiourea; N,N′-dimethylthiourea,N,N′-diethylthiourea, N,N′-diphenylthiourea; thiocyanates,tetramethylthiuram disulfide; 2-mercaptobenzothiazole or salts thereof(especially sodium 2-mercaptobenzothiazole), 2-mercaptobenzimidazole orsalts thereof (especially sodium 2-mercaptobenzimidazole); sodiumdimethyldithiocarbamate; 2,2′-dithiobis(benzothiazole),4,4′-thiobis(6-t-butyl-m-cresol), dicyandiamide, guanidine, cyanamide,paramethoxyphenol, 2,6-di-t-butyl-4-methylphenol, butylhydroxyanisole,8-hydroxychinoline, 2,5-di(t-amyl)hydroquinone,5-hydroxy-1,4-naphthoquinone, 2,5-di(t-amyl)hydroquinone, dimedone,propyl 3,4,5-trihydroxybenzoate, ammonium N-nitrosophenylhydroxylamine,4-hydroxy-2,2,6,6-tetramethyoxylpiperidine,(N-(1,3-dimethylbutyl)N′-phenyl-p-phenylenediamine and1,2,2,6,6-pentamethyl-4-piperidinol (PMP).

In a preferred embodiment, the stabilizer St is at least one compoundselected from the group consisting of thiourea; N,N′-dimethylthiourea,N,N′-diethylthiourea, N,N′-diphenylthiourea; thiocyanates,tetramethylthiuram disulfide; 2-mercaptobenzothiazole or salts thereof(especially sodium 2-mercaptobenzothiazole); sodiumdimethyldithiocarbamate; 2,2′-dithiobis(benzothiazole),4,4′-thiobis(6-t-butyl-m-cresol), dicyandiamide, guanidine, cyanamide,2,6-di-t-butyl-4-methylphenol, butylhydroxyanisole, 8-hydroxychinoline,2,5-di(t-amyl)hydroquinone, 5-hydroxy-1,4-naphthoquinone,2,5-di(t-amyl)hydroquinone, propyl 3,4,5-trihydroxybenzoate, ammoniumN-nitrosophenylhydroxylamine,4-hydroxy-2,2,6,6-tetramethyoxylpiperidine,(N-(1,3-dimethylbutyl)N′-phenyl-p-phenylenediamine and1,2,2,6,6-pentamethyl-4-piperidinol (PMP).

In one embodiment, the invention relates to a process for producing acomposition comprising at least one acrylamide polymer P and at leastone stabilizer St, where the stabilizer St is at least one mercaptocompound, especially a mercapto compound selected from the groupconsisting of 2-mercaptobenzothiazole, 2-mercaptobenzothiazole and saltsthereof (for example sodium salts).

More preferably, the stabilizer St is 2-mercaptobenzothiazole and/orsalts thereof, for example sodium 2-mercaptobenzothiazole (Na-MBT). In apreferred embodiment, at least one, preferably exactly one, mercaptocompound, preferably sodium 2-mercaptobenzothiazole (Na-MBT), is used asthe sole stabilizer St.

A mercapto compound in the context of the present invention is anorganic compound having at least one —S—H (thiol group) and/or —S-Mgroup where M is a metal ion, especially an alkali metal ion.

The stabilizer used is preferably exclusively one or more of theabove-described stabilizers St. Alternatively, it is possible to combinethe above-described stabilizer St with other known stabilizers, forexample sacrificial reagents (such as alcohols).

The acrylamide polymer P is treated in accordance with the inventionwith the stabilizer St in the form of an aqueous solution SS, preferablyusing water as solvent, or a mixture of water and one or more suitablewater-miscible organic solvents, where the proportion of water isgenerally at least 85% by weight, preferably at least 95% by weight andmore preferably at least 98% by weight, based on the overall solvent.The above-described embodiments of the solvent So apply to the solventfor the aqueous solution SS.

Preferably, in step c), the polymer gel is treated with an aqueoussolution SS comprising 1% to 50% by weight, preferably 5% to 40% byweight, further preferably 1% to 15% by weight, especially preferably 5%to 12% by weight, equally preferably 20% to 50% by weight, based on theoverall aqueous solution SS, of the at least one stabilizer St.

In a preferred embodiment, the aqueous solution SS comprises 20% to 50%by weight, preferably 30% to 50% by weight, more preferably 40% to 50%by weight, based on the overall aqueous solution SS, of sodium2-mercaptobenzothiazole as stabilizer St.

In a preferred embodiment, the aqueous solution SS comprises 1% to 15%by weight, especially preferably 5% to 12% by weight, based on theoverall aqueous solution SS, of 1,2,2,6,6-pentamethyl-4-piperidinol asstabilizer St.

Preferably, the concentration of the stabilizer St is in the range from0.1% to 10% by weight, preferably from 0.2% to 2% by weight, especiallypreferably from 0.25% to 1% by weight, based on the acrylamide polymerP, where the total mass is based on the sum total of all the monomersused. Alternatively, it is also possible to take the total mass of thedry acrylamide polymer P as the basis here. The concentration of thestabilizer St based on the acrylamide polymer is typically determinedvia the amount of the aqueous solution SS with which the polymer gel istreated and which is applied to the polymer gel in the process.

Preferably, the polymer gel is treated in step c) by spraying theaqueous solution SS onto the polymer gel or by mixing the polymer gelwith the aqueous solution SS.

In a preferred embodiment, the polymer gel is treated in step c) byadding the aqueous solution SS to the polymer gel in a screw.Advantageously, the addition of the aqueous solution SS in a screw, forexample a conveying screw or an extrusion screw, results in good mixingof the polymer gel with the aqueous solution SS. Screws typicallycomprise a screw trough or a screw pipe, a screw shaft with screw threadand a drive unit.

The aqueous solution SS can be added to the polymer gel in a conveyingscrew, in which case the conveying screw serves, for example, to removethe polymer gel from the polymerization reactor or to feed it and/orremove it from further comminution and/or drying steps after thepolymerization. The addition is typically effected through holes in theouter screw pipe. The addition of the aqueous solution SS to the polymergel in the screw can be effected, for example, via spray nozzles.

In a further preferred embodiment, the polymer gel is treated with theaqueous solution SS (step c)) in a pelletizing apparatus. In oneembodiment, a pelletizing apparatus has a perforated plate and a knifefor commuting the polymer gel (in a similar manner to a meat grinder).Often, a pelletizing apparatus comprises a screw (conveying screw,extrusion screw) which moves the polymer gel in the direction of theperforated plate. More particularly, in this embodiment, the aqueoussolution SS can be added directly upstream of the knife or upstream ofthe perforated plate of the pelletizing apparatus and/or in the regionof the conveying screw of the pelletizing apparatus. More particularly,such intimate mixing of the polymer gel and the aqueous solution SS canbe effected before and/or during the comminution of the polymer gel.This embodiment is suitable both in the case of a continuouspolymerization and in the case of a batchwise polymerization (see stepb).

In a further preferred embodiment, the polymerization (step b) iseffected continuously and the aqueous SS comprising the stabilizer St isadded to the polymer gel in a conveying screw with which the polymer gelis discharged continuously from the polymerization reactor.

In a further preferred embodiment, the polymerization (step b) iseffected batchwise, the polymer gel is withdrawn from the polymerizationreactor as described above and the aqueous SS comprising the stabilizerSt is added in an apparatus for comminuting the polymer gel, especiallyin an apparatus in which the polymer gel is comminuted with rotatingknives (in a similar manner to a meat grinder). In the case of abatchwise polymerization in step b), the polymer gel can also be treatedwith the aqueous solution SS in the region of a conveying screw withwhich the polymer gel is sent to further process steps, for example apelletizing apparatus and/or a drying apparatus.

In a further preferred embodiment, the polymer gel is treated in step c)by spraying the aqueous solution SS onto the polymer gel.

The spray application of the aqueous solution SS can be effected here,for example, after the first coarse comminution of the polymer gel afterthe withdrawal from the polymerization reactor to give polymer gelparticles having a median diameter in the range from 5 to 50 cm.

In a further embodiment, the aqueous solution SS comprising at least onestabilizer St can be sprayed onto the polymer gel in a belt drier; thespray application is typically effected here onto the polymer geldistributed on the belt, before and/or on commencement of drying.Typically, this embodiment gives polymer gel pellets having a mediansize of the polymer gel particles in the range from 0.2 to 3 cm.

In a further embodiment, the aqueous solution SS comprising at least onestabilizer St can be sprayed onto the polymer gel in a fluidized beddrier; the spray application is typically effected here onto the polymergel before and/or on commencement of drying. Typically, this embodimentgives polymer gel pellets having a median size of the polymer gelparticles in the range from 0.2 to 3 cm.

In a particularly preferred embodiment, the aqueous solution SS issprayed onto the polymer gel in step c) with prior comminution of thepolymer gel so as to obtain a median size of the polymer gel particlesin the range from 0.2 to 3 cm.

In a preferred embodiment, the polymer gel in step c) has a watercontent in the range from 50% to 80% by weight, preferably from 60% to75% by weight, more preferably from 60% to 70% by weight, based on theoverall polymer gel.

Preferably, the polymerization product obtained in step b) (acrylamidepolymer P in the form of a polymer gel) is used without drying in thedownstream steps, especially in downstream step c).

Alternatively, it is possible to remove a portion of the solvent So fromthe polymer gel, if the water content of the polymer gel is as requiredin step c).

Optional Step d)—Drying

The treatment of the polymer gel with the aqueous solution SS ispreferably followed by drying of the polymer gel in the optional stepd). The drying can be effected, for example, in a fluid bed drier or abelt drier. The person skilled in the art is aware of processes andapparatus for drying the polymer gel. Preferably, the polymer gel ispelletized prior to drying to obtain polymer gel pellets having a medianparticle diameter in the range from 0.3 to 2 cm.

Preferably, the process of the invention comprises, as step d), thedrying of the polymer gel at temperatures below 100° C., preferably attemperatures in the range from 40 to 60° C. To avoid conglutination, asuitable separating agent can be added to the composition. Typically,the separating agent is used in the pelletization of the composition.Typically, the drying affords a composition comprising at least oneacrylamide copolymer P and at least one stabilizer St in the form ofpellets or powder.

Optional Step e)—Comminution of the Polymer Gel

The process of the invention may comprise, in one or more optional stepse), the comminution of the polymer gel formed in step b) and/or step c).

Typically, the polymer gel after the above-described polymerization(step b) is in the form of a gel block. This polymer gel can first becomminuted in one or more steps e). The comminuting can be effected withthe aid of the processes known to those skilled in the art, for examplewith the aid of an extrusion screw, an apparatus in which the polymergel is comminuted with rotating knives (in a similar manner to a meatgrinder), and/or a pelletizing apparatus.

In one embodiment, the polymer gel is comminuted in step e) in such away that a coarse comminution of the polymer gel block is effectedfirst. A coarse comminution is obtained, for example, in an apparatus inwhich the polymer gel is comminuted with rotating knives (in a similarmanner to a meat grinder). Typically, this coarse comminution can givepolymer gel particles having a median diameter in the range from 5 to 50cm.

It is possible to further comminute the polymer gel before or after thetreatment with the aqueous solution SS (process step c of theinvention), for example in a pelletizing apparatus. Typically, apelletizing apparatus has a perforated plate and a knife for comminutingthe polymer gel (in a similar manner to a meat grinder). The size of theresultant polymer gel particles can typically be determined via thechoice of perforated plate, i.e. the size of the holes in the perforatedplate. Typically, a pelletizing apparatus can give polymer particleshaving a median diameter in the range from 0.3 to 2 cm, preferably 0.5to 2 cm.

Further Process Steps

The process of the invention may optionally comprise further processsteps, for example blending, extruding and/or grinding. It is possible,for example, to grind the polymer gel, especially after the drying(optional step d)), to give a polymer powder. This can be effected withthe aid of suitable apparatuses known to those skilled in the art, forexample with the aid of a centrifugal mill.

The composition obtained by the process of the invention, comprising atleast one acrylamide polymer P and at least one stabilizer St, istypically used in the form of an aqueous solution in the course ofemployment (polymer flooding) at the site of use, and is thereforetypically dissolved in water on site. In the course of this, there maytypically be unwanted formation of lumps. In order to avoid this, anauxiliary which accelerates or improves the dissolution of the driedpolymer in water may be added at the early stage of the synthesis to thedescribed compositions comprising acrylamide polymer P and stabilizerSt.

The aqueous solution SS is preferably produced by dissolving the atleast one stabilizer St and optionally further additives in water or amixture of water with a water-miscible organic solvent.

The present invention is elucidated in detail by the examples whichfollow.

EXAMPLES Example 1 Preparation of the Acrylamide Copolymers 1.1Preparation of the Macromonomer Used (Monomer a) Abbreviations

-   HBVE hydroxybutyl vinyl ether, H₂C═CH—O—(CH₂)₄—OH-   EO ethylene oxide-   BuO butylene oxide (>85% by weight of 1,2-butylene oxide)

By alkoxylation of HBVE with 24.5 units of EO, followed by 16 units ofBuO, followed by 3.5 units of EO, a macromonomer (monomer (a)) of thefollowing formula was prepared:H₂C═CH—O—(CH₂)₄—O-(EO)_(24.5)(BuO)₁₆(EO)_(3.5)

A 2 L pressure autoclave with anchor stirrer was initially charged with135.3 g (1.16 mol) of hydroxybutyl vinyl ether (HBVE) (stabilized with100 ppm potassium hydroxide (KOH)), and the stirrer was switched on.1.06 g of potassium methoxide (KOMe) solution (32% KOMe in methanol(MeOH), corresponds to 0.0048 mol of potassium) were fed in and thestirred vessel was evacuated to a pressure of 10-20 mbar, heated to 65°C., and operated at 65° C. and a pressure of 10-20 mbar for 70 min. MeOHwas distilled off. The vessel was purged three times with N₂ (nitrogen).Thereafter, the vessel was checked for pressure retention, a pressure of0.5 bar gauge (1.5 bar absolute) was established and the vessel washeated to 120° C. The vessel was decompressed to 1 bar absolute and 1126g (25.6 mol) of ethylene oxide (EO) were metered in until p_(max) was3.9 bar absolute and T_(max) was 150° C. After 300 g EO had been meteredin, the metered addition was stopped (about 3 h after commencement), andthe mixture was left for 30 min and decompressed to 1.3 bar absolute.Thereafter, the rest of the EO was metered in. The metered addition ofEO including the decompression took a total of 10 h.

The mixture was stirred at about 145-150° C. until pressure was constant(1 h), cooled to 100° C. and freed of low boilers at a pressure of lessthan 10 mbar for 1 h. The material was dispensed at 80° C. under N₂.

Analysis (OH number, GPC, 1H NMR in CDCl₃, 1H NMR in MeOD) confirmed thestructure HBVE-22EO.

A 2 L pressure autoclave with anchor stirrer was initially charged with588.6 g (0.543 mol) of HBVE-22EO, and the stirrer was switched on.Thereafter, 2.39 g of 50% NaOH solution (0.030 mol of NaOH, 1.19 g ofNaOH) were added, a reduced pressure of <10 mbar was applied, and themixture was heated to 100° C. and kept at that temperature for 80 min,in order to distill off the water. The vessel was purged three timeswith N₂. Thereafter, the vessel was checked for pressure retention, apressure of 0.5 bar gauge (1.5 bar absolute) was set, the mixture washeated to 127° C. and then the pressure was adjusted to 1.6 barabsolute. 59.7 g (1.358 mol) of EO were metered in at 127° C.; p_(max)was 3.9 bar absolute. The mixture was left for 30 min until a constantpressure was established, then decompressed to 1.0 bar absolute. 625.5 g(8.688 mol) of BuO (butylene oxide) were metered in at 127° C.; p_(max)was 3.1 bar absolute. An intermediate decompression was conductedbecause of the increase in the fill level. The metered addition of BuOwas stopped, and the mixture was left to react for 1 h until thepressure was constant and decompressed to 1.0 bar absolute. Thereafter,the metered addition of BuO was continued. P_(max) was still 3.1 bar(first decompression after 610 g of BuO, total metering time for BuO 8 hincluding wait for decompression). After the metered addition of BuO hadended, reaction was allowed to continue for 8 h and the mixture was thenheated to 135° C. The vessel was decompressed to 1.6 bar absolute.Thereafter, 83.6 g (1.901 mol) of EO (ethylene oxide) was metered in at135° C.; p_(max) was 3.1 bar absolute. After the metered addition of EOhad ended, reaction was allowed to continue for 4 h. The mixture wascooled to 100° C.; residual oxide was drawn off until the pressure wasbelow 10 mbar for at least 10 min. Then 0.5% water was added at 120° C.,followed by drawing-off until the pressure was below 10 mbar for atleast 10 min. The vacuum was broken with N₂, and 100 ppm BHT were added.Dispensing was effected at 80° C. under N₂.

Analysis (mass spectrum, GPC, 1H NMR in CDCl3, 1H NMR in MeOD) confirmedthe mean composition HBVE-24.5EO-16 BuO-3.5 EO.

1.2 Preparation of the Acrylamide Copolymers

In examples P1 to P5 and comparative examples C1 to C5, and also P11 toP15 and C13 to C17, which follow, acrylamide copolymers comprising 47.6%by weight of acrylamide, 50.5% by weight of the sodium salt of2-acrylamido-2-methylpropanesulfonic acid (Na-ATBS) and 1.9% by weightof the macromonomer described above under 1.1 were prepared.

In examples P6 to P10 and comparative examples C6 to C11, and also P16to P20 and C18, which follow, acrylamide copolymers comprising 69.4% byweight of acrylamide and 30.6% by weight of sodium acrylate (monomer b2)were prepared.

Each polymerization was effected by means of adiabatic gelpolymerization.

The stabilizer S1 used was sodium 2-mercaptobenzothiazole (Na-MBT), withaddition of various amounts of Na-MBT in the range from 0% to 1% byweight, based on the total weight of the monomers, in different ways.

The stabilizer S2 used was 1,2,2,6,6-pentamethyl-4-piperidinol (PMP),with addition of various amounts of PMP in the range from 0% to 1% byweight, based on the total weight of the monomers, in different ways.

The acrylamide copolymers were characterized as described in example 2.The results are compiled in tables 1 to 4.

Comparative Example C1 Without Addition of Na-MBT (Blank Experiment)

A plastic bucket having a magnetic stirrer, pH meter and thermometer wasinitially charged with 146.36 g of a 50% aqueous solution of Na-ATBS andthen the following were added successively: 105.8 g of distilled water,0.4 g of a commercial silicone-based defoamer (Dow Corning® AntifoamEmulsion RD), 2.8 g of the above-described macromonomer, 132.47 g ofacrylamide (50% solution in water), 1.2 g of a 5% aqueous solution ofdiethylentriaminepentaacetic acid, pentasodium salt, and 3.0 g of thenonionic surfactant Lutensol® TO 15 (iC13-(EO)₁₅H).

After adjustment to pH 6.4 with a 20% or 2% sulfuric acid solution andaddition of the rest of the water to attain the desired monomerconcentration of 37% by weight (total amount of water minus the amountof water already added, minus the amount of acid required), the monomersolution was adjusted to the initiation temperature of 2° C. Thesolution was transferred to a thermos flask, the temperature sensor forthe temperature recording was attached and the mixture was purged withnitrogen for 30 minutes, and the polymerization was initiated with 1.6mL of a 10% aqueous solution of the water-soluble azo initiator2,2′-azobis(2-methylpropionamidine) dihydrochloride (Wako V-50), 0.12 mLof a 1% t-BHPO solution (tert-butyl hydroperoxide) and 0.24 mL of a 1%sodium sulfite solution. With the onset of the polymerization, thetemperature rose to 80° C. to 90° C. within about 25 minutes. A solidpolymer gel was obtained.

After the polymerization, the gel block was comminuted with the aid of ameat grinder. The gel pellets obtained were dried in a fluidized beddrier at 55° C. for two hours. This gave hard white pellets which wereconverted to a pulverulent state by means of a centrifugal mill.

Comparative Example C2 Addition of Na-MBT to the Polymerization Mixturein an Amount of 0.1% by Weight, Based on the Acrylamide Copolymer

A plastic bucket having a magnetic stirrer, pH meter and thermometer wasinitially charged with 146.36 g of a 50% aqueous solution of Na-ATBS andthen the following were added successively: 105.8 g of distilled water,0.4 g of a commercial silicone-based defoamer (Dow Corning® AntifoamEmulsion RD), 2.8 g of the above-described macromonomer according to1.1, 132.47 g of acrylamide (50% solution in water), 1.2 g of a 5%aqueous solution of diethylentriaminepentaacetic acid, pentasodium salt,and 3.0 g of the nonionic surfactant Lutensol® TO 15 (iC13-(EO)₁₅H).Subsequently, 0.16 g of sodium 2-mercaptobenzothiazole (Na-MBT) wasadded.

After adjustment to pH 6.4 with a 20% or 2% sulfuric acid solution andaddition of the rest of the water to attain the desired monomerconcentration of 37% by weight (total amount of water minus the amountof water already added, minus the amount of acid required), the monomersolution was adjusted to the initiation temperature of 2° C. Thesolution was transferred to a thermos flask, the temperature sensor forthe temperature recording was attached and the mixture was purged withnitrogen for 30 minutes, and the polymerization was initiated with 1.6mL of a 10% aqueous solution of the water-soluble azo initiator2,2′-azobis(2-methylpropionamidine) dihydrochloride (Wako V-50), 0.12 mLof a 1% t-BHPO solution and 0.24 mL of a 1% sodium sulfite solution.With the onset of the polymerization, the temperature rose to 80° C. to90° C. within about 25 minutes.

A solid polymer gel was obtained. After the polymerization, the gelblock was comminuted with the aid of a meat grinder. The gel pelletsobtained were dried in a fluidized bed drier at 55° C. for two hours.This gave hard white pellets which were converted to a pulverulent stateby means of a centrifugal mill.

Comparative Examples C3 to C5 Addition of Na-MBT to the PolymerizationMixture

Acrylamide copolymers C3 to C5 were prepared as described above underexample C2, except with addition of different amounts of sodium2-mercaptobenzothiazole to the polymerization mixture. Concentrations ofNa-MBT of 0.25% by weight, 0.5% by weight and 0.75% by weight, based ineach case on the acrylamide copolymer, were obtained.

Example P1 Spray Application of an Aqueous Solution of Na-MBT to theMoist Polymer Gel

A plastic bucket having a magnetic stirrer, pH meter and thermometer wasinitially charged with 146.36 g of a 50% aqueous solution of Na-ATBS andthen the following were added successively: 105.8 g of distilled water,0.4 g of a commercial silicone-based defoamer (Dow Corning® AntifoamEmulsion RD), 2.8 g of the above-described macromonomer, 132.47 g ofacrylamide (50% solution in water), 1.2 g of a 5% aqueous solution ofdiethylentriaminepentaacetic acid, pentasodium salt, and 3.0 g of thenonionic surfactant Lutensol® TO 15 (iC13-(EO)₁₅H).

After adjustment to pH 6.4 with a 20% or 2% sulfuric acid solution andaddition of the rest of the water to attain the desired monomerconcentration of 37% by weight (total amount of water minus the amountof water already added, minus the amount of acid required), the monomersolution was adjusted to the initiation temperature of 2° C. Thesolution was transferred to a thermos flask, the temperature sensor forthe temperature recording was attached and the mixture was purged withnitrogen for 30 minutes, and the polymerization was initiated with 1.6mL of a 10% aqueous solution of the water-soluble azo initiator2,2′-azobis(2-methylpropionamidine) dihydrochloride (Wako V-50), 0.12 mLof a 1% t-BHPO solution and 0.24 mL of a 1% sodium sulfite solution.With the onset of the polymerization, the temperature rose to 80° C. to90° C. within about 25 minutes. A solid polymer gel was obtained.

After the polymerization, the gel block was comminuted with the aid of ameat grinder. Thereafter, onto the moist polymer gel a solution SScomprising 30% by weight of Na-MBT was sprayed and mixed with thepolymer gel. A concentration of Na-MBT of 0.1% by weight, based on theacrylamide copolymer, was obtained.

The median size of the gel particles was in the range from 5 to 20 mm.The water content of each polymer gel corresponds to the water contentin the monomer solution MS.

The resultant gel pellets were dried in a fluidized bed drier at 55° C.for two hours. This gave hard white pellets which were converted to apulverulent state by means of a centrifugal mill.

Examples P2 to P5 Spray Application of an Aqueous Solution of Na-MBT tothe Moist Polymer Gel

Acrylamide copolymers P2 to P5 were prepared as described above inexample P1, except with spray application of different amounts of sodium2-mercaptobenzothiazole to the moist polymer gel. Concentrations ofNa-MBT of 0.25% by weight, 0.5% by weight, 0.75% by weight and 1.00% byweight, based on the acrylamide copolymer, were obtained.

Comparative Example C6 Without Addition of Na-MBT (Blank Experiment)

A plastic bucket having a magnetic stirrer, pH meter and thermometer wasinitially charged with 104.92 g of a 35% solution of sodium acrylate,and then the following were added successively: 108.33 g of distilledwater, 160.16 g of acrylamide (50% solution), 1.2 g of Trilon C (5%solution) and 3 mL of a 4% ACVA solution.

After adjustment to pH 6.0 with a 20% or 2% sulfuric acid solution andaddition of the residual water (total amount of water minus the amountof water already added, minus the amount of acid required), the monomersolution was adjusted to the initiation temperature of 0° C. Thesolution was transferred to a thermos flask, the temperature sensor forthe temperature recording was attached and the mixture was purged withnitrogen for 30 minutes, and the polymerization was initiated with 3 mLof a 4% AIBN solution in methanol, 0.09 mL of a 1% t-BHP solution and0.18 mL of a 1% sodium sulfite solution.

Thereafter, the gel block was comminuted with the aid of a meat grinderand the resultant gel pellets were dried in a fluidized bed drier at 55°C. for two hours. This gave hard white pellets which were converted to apulverulent state by means of a centrifugal mill.

Comparative Examples C7 to C10 Addition of Na-MBT to the PolymerizationMixture

Acrylamide copolymers C7 to C10 were prepared as described above inexample C6, except with addition of different amounts of sodium2-mercaptobenzothiazole to the polymerization mixture, namely 0.25% byweight, 0.5% by weight and 0.75% by weight, based in each case on theacrylamide copolymer. The addition of Na-MBT was effected in accordancewith example C2.

Comparative Example C11 Spray Application of an Aqueous Solution ofNa-MBT to the Dried Polymer Gel

An acrylamide copolymer C11 was prepared as described in example C6,except with spray application of an aqueous sodium2-mercaptobenzothiazole solution to the dried polymer gel. Aconcentration of Na-MBT of 0.75% by weight, based on the acrylamidecopolymer, was obtained.

The gel block which was obtained after the polymerization as incomparative example C6 was comminuted with the aid of a meat grinder andthe resultant gel pellets were dried in a fluidized bed drier at 55° C.for two hours. This gave hard white pellets which were converted to apulverulent state by means of a centrifugal mill.

In a paddle wheel mixer, a 30% by weight solution of Na-MBT was sprayedonto the polymer powder and mixed with the polymer powder by the motionof the paddle wheels. After drying, the polymer powder had a solidscontent of about 92% by weight. This solids content fell to about 89% byweight as a result of the addition of the Na-MBT solution.

Example P6 Spray Application of an Aqueous Solution of Na-MBT to theMoist Polymer Gel

A plastic bucket having a magnetic stirrer, pH meter and thermometer wasinitially charged with 104.92 g of a 35% solution of sodium acrylate,and then the following were added successively: 108.33 g of distilledwater, 160.16 g of acrylamide (50% solution), 1.2 g of Trilon C (5%solution) and 3 mL of a 4% 4,4′-azobis-4-cyanovaleric acid (ACVA)solution.

After adjustment to pH 6.0 with a 20% or 2% sulfuric acid solution andaddition of the residual water (total amount of water minus the amountof water already added, minus the amount of acid required), the monomersolution was adjusted to the initiation temperature of 0° C. Thesolution was transferred to a thermos flask, the temperature sensor forthe temperature recording was attached and the mixture was purged withnitrogen for 30 minutes, and the polymerization was initiated with 3 mLof a 4% AIBN solution in methanol, 0.09 mL of a 1% t-BHP solution and0.18 mL of a 1% sodium sulfite solution.

After the polymerization, the gel block was comminuted with the aid of ameat grinder. Thereafter, onto the moist polymer gel a solution SScomprising 30% by weight of Na-MBT was sprayed and mixed with thepolymer gel. A concentration of Na-MBT of 0.1% by weight, based on theacrylamide copolymer, was obtained.

The median size of the gel particles was in the range from 5 to 20 mm.The water content of each polymer gel corresponds to the water contentin the monomer solution MS.

The resultant gel pellets were dried in a fluidized bed drier at 55° C.for two hours. This gave hard white pellets which were converted to apulverulent state by means of a centrifugal mill.

Examples P7 to P10 Spray Application of an Aqueous Solution of Na-MBT tothe Moist Polymer Gel

Acrylamide copolymers P7 to P10 were prepared as described above inexample P6, except with spray application of different amounts of sodium2-mercaptobenzothiazole to the moist polymer gel. Concentrations ofNa-MBT of 0.25% by weight, 0.5% by weight, 0.75% by weight and 1.00% byweight, based on the acrylamide copolymer, were obtained.

The above-described comparative experiments and inventive experimentswere repeated, except using, rather than the stabilizer St1 (Na-MBT),the stabilizer St2 (1,2,2,6,6-pentamethyl-4-piperidinol (PMP)).

Comparative Examples C12 to C17 Addition of PMP to the PolymerizationMixture

Comparative example C12 is a repetition of comparative example C1,except with no stabilizer addition. As a result of the use of adifferent raw material batch, a deviation in the viscosity is found inthis series of experiments.

Acrylamide copolymers C13 to C17 were prepared as described above inexample C2, except with addition, rather than of the Na-MBT, ofdifferent amounts of 1,2,2,6,6-pentamethyl-4-piperidinol (PMP) to thepolymerization mixture. Concentrations of PMP of 0.10% by weight, 0.25%by weight, 0.5% by weight, 0.75% by weight and 1.00% by weight, based ineach case on the acrylamide copolymer, were obtained.

Examples P11 to P15 Spray Application of an Aqueous Solution of PMP tothe Moist Polymer Gel

Acrylamide copolymers P11 to P15 were prepared as described above inexample P1, except with spray application, rather than of the Na-MBT, ofdifferent amounts of 1,2,2,6,6-pentamethyl-4-piperidinol (PMP) to themoist polymer gel.

A solution SS comprising 8% by weight of PMP was sprayed onto the moistpolymer gel and mixed with the polymer gel. Concentrations of PMP of0.10% by weight, 0.25% by weight, 0.5% by weight, 0.75% by weight and1.00% by weight, based on the acrylamide copolymer, were obtained.

Comparative Example C18

Comparative example C18 is a repetition of comparative example C6,except with no stabilizer addition.

Examples P16 to P20 Spray Application of an Aqueous Solution of PMP tothe Moist Polymer Gel

Acrylamide copolymers P16 to P20 were prepared as described above inexample P6, except with spray application, rather than of the Na-MBT, ofdifferent amounts of 1,2,2,6,6-pentamethyl-4-piperidinol (PMP) to themoist polymer gel.

A solution SS comprising 8% by weight of PMP was sprayed onto the moistpolymer gel and mixed with the polymer gel. Concentrations of PMP of0.10% by weight, 0.25% by weight, 0.5% by weight, 0.75% by weight and1.00% by weight, based on the acrylamide copolymer, were obtained.

2 Characterization of the Acrylamide Copolymers

2.1 Determination of Viscosity

The viscosity of the acrylamide copolymers C1 to C5 and P1 to P5, andalso C12 to C17 and P11 to P15, was measured in synthetic seawater at60° C. with a polymer concentration of 2000 ppm. The viscosity of theacrylamide copolymers C6 to C11 and P6 to P10, and also C18 and P16 toP20, was measured in a salt solution comprising 12 261 ppm NaCl, 362 ppmCaCl₂ and 309 ppm MgCl₂, at 25° C. with a polymer concentration of 1500ppm.

The viscosity was measured with a Brookfield LVDV-II viscometer having aUL adapter. A speed of rotation of 6 rpm was used.

2.2 Determination of Gel Content

In each case 0.1 g of the acrylamide copolymers obtained in 1.2(acrylamide copolymers C1 to C11 and P1 to P10) was dissolved in 1 L oftap water at 25° C. (concentration 1000 ppm). The solution was filteredthrough a 200 μm sieve and the amount of polymer gel remaining on thesieve was determined.

2.3 Determination of Filterability—MPFR (Millipore Filtration Ratio)

In addition, the filterability of the acrylamide copolymers C1 to C11and P1 to P10 was examined with the aid of the MPFR value (Milliporefiltration ratio). The MPFR value (Millipore filtration ratio) indicatesthe deviation of a polymer solution from ideal filtration behavior, withno reduction in the filtration rate as a result of blockage of thefilter in the case of ideal filtration behavior.

To determine the MPFR values, about 200 mL of polymer solution having aconcentration of 1000 ppm were filtered at a pressure of 1.38*10⁵ Pathrough a polycarbonate filter having a pore size of 5 μm. In the courseof this, the amount of filtrate was recorded as a function of time. TheMPFR value was calculated according to the following formula:MPFR=(t _(180 g) −t _(160 g))/(t _(80 g) −t _(60 g)),with t_(index)=time before measurement of the amount of filtratereported, i.e. t_(180 g) is the time before 180 g of filtrate weremeasured. According to API RP 63 (“Recommended Practices for Evaluationof Polymers Used in Enhanced Oil Recovery Operations”, AmericanPetroleum Institute), values of less than 1.3 are acceptable. In thecase of ideal filterability, the MPFR value is 1.

3. Results

The acrylamide copolymers C1 to C11 and P1 to P10 (with Na-MBTstabilizer) and C12 to C18 and P11 to P20 (with PMP stabilizer) obtainedaccording to example 1.2 were characterized as described above. Theresults are summarized in tables 1 to 4 below.

TABLE 1 Acrylamide copolymers (C1 to C5 and P1 to P5) formed fromacrylamide, Na-ATBS and macromonomer according to 1.1 Addition of Na-MBT% by weight Gel Mode of based on Viscosity content Example additionpolymer [mPas] [mL] MPFR C1 — 0 190 1 1.30 C2 to monomer 0.10 200 <11.30 solution C3 to monomer 0.25 210 0 1.25 solution C4 to monomer 0.50150 0 1.20 solution C5 to monomer 0.75 120 0 1.22 solution P1 spray 0.10220 0 1.27 application to moist gel P2 spray 0.25 230 0 1.16 applicationto moist gel P3 spray 0.50 250 0 1.0 application to moist gel P4 spray0.75 270 0 1.0 application to moist gel P5 spray 1.00 270 0 1.0application to moist gel

TABLE 2 Acrylamide copolymers (C6 to C11 and P6 to P10) formed fromacrylamide and sodium acrylate Addition of Na-MBT % by weight Gel Modeof based on Viscosity content Example addition polymer [mPas] [mL] MPFRC6  — 0 25 1 1.29 C7  to monomer 0.10 27 <1 1.20 solution C8  to monomer0.25 28 0 1.15 solution C9  to monomer 0.50 Na-MBT precipitates outsolution C10 to monomer 0.75 Na-MBT precipitates out solution C11 spray0.75 24 1 1.30 application to dry gel P6  spray 0.10 28 0 1.21application to moist gel P7  spray 0.25 31 0 1.14 application to moistgel P8  spray 0.50 32 0 1.02 application to moist gel P9  spray 0.75 340 1.01 application to moist gel P10 spray 1.00 34 0 1.04 application tomoist gel

It has been found that, surprisingly, the spray application of Na-MBT tothe moist polymer gel increases the viscosity of the polymer and reducesthe MPFR value. This is not the case when the Na-MBT is only sprayedonto the dried polymer (see C11). Comparative examples C1 to C10 showthat, given the same amount of the stabilizer, higher viscosities andlower MPFR values are obtained when the stabilizer (Na-MBT) is not addeddirectly to the monomer solution but applied to the moist polymer geldirectly after the gel polymerization. The treatment of the moistpolymer gel with the stabilizer has an advantageous effect on thepolymer properties. It is found that the insoluble gel fractions in theacrylamide copolymer can be distinctly reduced with the aid of thepreparation process of the invention. This process variant thus led to adistinct improvement in the properties of the acrylamide copolymers withrespect to the use thereof in tertiary mineral oil production.

TABLE 3 Acrylamide copolymers (C12 to C17 and P11 to P15) formed fromacrylamide, Na-ATBS and macromonomer according to 1.1 Addition of PMP %by weight Gel Mode of based on Viscosity content Example additionpolymer [mPas] [mL] MPFR C12 — 0 170 0 1.29 C13 to monomer 0.10 200 01.27 solution C14 to monomer 0.25 270 0 1.18 solution C15 to monomer0.50 250 0 1.14 solution C16 to monomer 0.75 230 0 1.13 solution C17 tomonomer 1 210 0 1.12 solution P11 spray 0.10 220 <1 1.25 application tomoist gel P12 spray 0.25 240 <1 1.20 application to moist gel P13 spray0.50 250 0 1.17 application to moist gel P14 spray 0.75 250 0 1.15application to moist gel P15 spray 1.00 250 0 1.17 application to moistgel

TABLE 4 Acrylamide copolymers (C18 and P16 to P20) formed fromacrylamide and sodium acrylate Addition of PMP % by weight Gel Mode ofbased on Viscosity content Example addition polymer [mPas] [mL] MPFRC6/C18 — 0 25 1 1.29 P16 spray 0.10 27 <1 1.20 application to moist gelP17 spray 0.25 28 0 1.18 application to moist gel P18 spray 0.50 30 01.15 application to moist gel P19 spray 0.75 29 0 1.13 application tomoist gel P20 spray 1.00 29 0 1.14 application to moist gel

In the case of PMP as stabilizer St too, it is observed that improved,i.e. higher, viscosity values of the acrylamide polymers can be obtainedby the process of the invention.

It is additionally advantageous that higher concentrations of Na-MBT andPMP in the acrylamide polymer P can be obtained by the process of theinvention, whereas the addition of Na-MBT to the monomer solution islimited because of other factors. For example, the Na-MBT canprecipitate out at relatively high concentrations in the polymerizationmixture (monomer solution MS) (see table 2).

The invention claimed is:
 1. A process for producing a compositioncomprising at least one water-soluble acrylamide polymer P and at leastone stabilizer St for prevention of polymer degradation by molecularoxygen, comprising the following steps: a) providing an aqueous monomersolution MS comprising 20% to 45% by weight, based on the total amountof all the components of the aqueous monomer solution MS, of at leastone ethylenically unsaturated monomer, at least one monomer being(meth)acrylamide, at least one initiator I for the free-radicalpolymerization and at least one solvent So comprising at least 50% byweight, based on the overall solvent So, of water; b) polymerizing theaqueous monomer solution MS to obtain the acrylamide polymer P in theform of a polymer gel; c) after the polymerization in step b), treatingthe polymer gel obtained in step b) having a water content in the rangeof from 50 to 80% by weight, based on the overall polymer gel, with anaqueous solution SS comprising 5 to 50% by weight, based on the overallaqueous solution SS, of the at least one stabilizer St; d) optionallydrying the polymer gel from step c).
 2. The process for producing acomposition according to claim 1, wherein the monomer solution MScomprises the following monomers: 30% to 100% by weight of(meth)acrylamide; 0% to 70% by weight of at least one anionic,monoethylenically unsaturated, hydrophilic monomer (b2); 0% to 70% byweight of at least one cationic, monoethylenically unsaturated,hydrophilic monomer (b3); 0% to 15% by weight of at least onemonoethylenically unsaturated monomer other than (meth)acrylamide andthe monomers (b2) and (b3); where the amounts are each based on thetotal amounts of all the monomers in the monomer solution MS.
 3. Theprocess for producing a composition according to claim 1, wherein themonomer solution MS comprises the following monomers: 60% to 75% byweight of (meth)acrylamide; 25% to 40% by weight of at least onemonoethylenically unsaturated hydrophilic monomer (b) selected from thegroup consisting of anionic, monoethylenically unsaturated, hydrophilicmonomers (b2) and cationic, monoethylenically unsaturated, hydrophilicmonomers (b3), where the amounts are each based on the total amounts ofall the monomers in the monomer solution MS.
 4. The process forproducing a composition according to claim 1, wherein the monomersolution MS comprises, as well as (meth)acrylamide, additionally atleast one hydrophilic, monoethylenically unsaturated anionic monomer(b2) comprising at least one acidic group selected from the groupconsisting of —COOH, SO₃H or —PO₃H₂ and salts thereof, and/or comprisesat least one cationic, monoethylenically unsaturated, hydrophilicmonomer (b3) comprising ammonium groups.
 5. The process for producing acomposition according to claim 1, wherein the monomer solution MScomprises at least one monomer selected from the group consisting of(meth)acrylamide, 2-acrylamido-2-methylpropanesulfonic acid, acrylicacid and their respective salts, with the proviso that at least 10% byweight, based on the total amount of all the monomers, of(meth)acrylamide is present.
 6. The process for producing a compositionaccording to claim 1, wherein the monomer solution MS comprises thefollowing monomers: 30% to 100% by weight of (meth)acrylamide; 0% to 15%by weight of at least one monoethylenically unsaturated, hydrophobicallyassociating monomer (a); 0% to 70% by weight of at least one anionic,monoethylenically unsaturated, hydrophilic monomer (b2); 0% to 70% byweight of at least one cationic, monoethylenically unsaturated,hydrophilic monomer (b3); 0% to 15% by weight of at least onemonoethylenically unsaturated monomer other than (meth)acrylamide andthe monomers (a), (b2) and (b3); where the amounts are each based on thetotal amounts of all the monomers in the monomer solution MS, and withthe proviso that the sum total of the monomers mentioned is 100% byweight.
 7. The process for producing a composition according to claim 1,wherein the proportion of (meth)acrylamide in the monomer solution MS isat least 45% by weight, based on the total amount of all the monomers.8. The process for producing a composition according to claim 1, whereinthe aqueous solution SS comprises 5% to 40% by weight, based on theoverall aqueous solution SS, of the at least one stabilizer St.
 9. Theprocess for producing a composition according to claim 1, wherein thestabilizer St is at least one compound selected from the groupconsisting of thiourea; N,N′-dimethylthiourea, N,N′-diethylthioureaN,N′-diphenylthiourea; thiocyanates, tetramethylthiuram disulfide;2mercaptobenzothiazole or salts thereof; sodium dimethyldithiocarbamate;2,2′-dithiobis(benzothiazole), 4,4′thiobis(6-t-butyl-m-cresol),dicyandiamide, guanidine, cyanamide, 2,6-di-t-butyl-4-methylphenol,butylhydroxyanisole, 8hydroxyquinoline 2,5-di(t-amyl)hydroquinone,5-hydroxy-1,4-naphthoquinone, 2,5-di(t-amyl)hydroquinone, propyl3,4,5-trihydroxybenzoate, ammonium N-nitrosophenylhydroxylamine,4-hydroxy-2,2,6,6-tetramethyoxylpiperidine,(N-(1,3-dimethylbutyl)-N′-phenyl-p-phenyIenediamine and1,2,2,6,6-pentamethyl-4-piperidinol.
 10. The process for producing acomposition according to claim 1, wherein the stabilizer St is sodium2mercaptobenzothiazole and/or 1,2,2,6,6-pentamethyl-4-piperidinol. 11.The process for producing a composition according to claim 1, whereinthe concentration of the stabilizer St is in the range from 0.1% to 10%by weight, based on the acrylamide polymer P, where the total mass isbased on the sum total of all the monomers used.
 12. The process forproducing a composition according to claim 1, wherein the treating ofthe polymer gel in step c) is effected by adding the aqueous solution SSto the polymer gel in a screw.
 13. The process for producing acomposition according to claim 1, wherein the treating of the polymergel in step c) is effected by spraying the aqueous solution SS onto thepolymer gel.
 14. The process for producing a composition according toclaim 1, wherein the process comprises, as step d), the drying of thepolymer gel at temperatures below 100° C.
 15. The process for producinga composition according to claim 1, wherein the monomer solution MScomprises the following monomers: 59% to 75% by weight, of(meth)acrylamide; 1% to 40% by weight, of at least one anionic,monoethylenically unsaturated, hydrophilic monomer (b2); 1% to 40% byweight, of at least one cationic, monoethylenically unsaturated,hydrophilic monomer (b3); 0% to 15% by weight of at least onemonoethylenically unsaturated monomer other than (meth)acrylamide andthe monomers (b2) and (b3); where the amounts are each based on thetotal amounts of all the monomers in the monomer solution MS.
 16. Theprocess for producing a composition according to claim 1, wherein themonomer solution MS comprises at least one monomer selected from thegroup consisting of (meth)acrylamide,2-acrylamido-2-methylpropanesulfonic acid, acrylic acid and theirrespective salts, with the proviso that more than 45% by weight, basedon the total amount of all the monomers, of (meth)acrylamide is present.17. The process for producing a composition according to claim 1,wherein the concentration of the stabilizer St is in the range from 0.2%to 2% by weight based on the acrylamide polymer P, where the total massis based on the sum total of all the monomers used.
 18. The process forproducing a composition according to claim 1, wherein the concentrationof the stabilizer St is in the range from 0.25% to 1% by weight, basedon the acrylamide polymer P, where the total mass is based on the sumtotal of all the monomers used.
 19. The process for producing acomposition according to claim 1, wherein the monomer solution MScomprises at least one monomer selected from the group consisting of(meth)acrylamide, 2-acrylamido-2-methylpropanesulfonic acid, acrylicacid and their respective salts, with the proviso that at least 15% byweight, based on the total amount of all the monomers, of(meth)acrylamide is present.